Glass microspheres made from a redox active glass

ABSTRACT

Microspheres comprising a plurality of hollow microspheres, each of the plurality of hollow microspheres comprising a plurality of glass walls, and a plurality of hollow spaces, wherein the plurality of glass walls enclosing at least one of the plurality of hollow spaces, wherein the plurality of glass walls comprising a second glass, wherein the second glass comprising a processed first glass melt, wherein the processed first glass melt comprising a melt of a batch and a plurality of redox active group components capable of providing at least one of a plurality of redox reactions and a plurality of events in the second glass.

FIELD OF INVENTION

The present invention is directed to glass microspheres and a method ofmanufacturing glass microspheres. More specifically, the presentinvention is directed to glass microspheres made from redox activeglass, and the method of their manufacture.

BACKGROUND OF THE INVENTION

Various methods are already known in the art for the manufacture ofglass microspheres.

In accordance with the methods available in the art, pre-formed glassparticles may be converted into glass bubbles or micro-balloons. Tocreate the glass bubbles the glass particles have to be post-modified tocontain the ingredients necessary for their expansion.

As known from the art, a silicate glass with over 14 wt % sodium oxideand 0.1 Fe₂O₃ is initially treated with high temperature steam and isused to form glass bubbles at about 1150-1200° C. In another knownexample, a silicate glass having a sodium oxide concentration of 13.5 wt% and a potassium oxide concentration of 3.2 wt %, with 0.2 wt % ofsulfur in the form of SO₄ is melted and pulverized. The so formed culletis dropped through a flame at about 1150-1200° C. to create a glassmicrosphere.

In accordance with other methods known in the art of glass microsphereproduction, a pre-melted glass frit is used to produce glassmicro-bubbles with a chemical composition, expressed in weight percent,of at least 67% SiO₂ , 8-15% RO, 3-8% R₂O, 2-6% B₂O₃, and 0.125-1.50%SO₃. The RO: R₂O weight ratio is in the range of 1.0-3.5.

From further art references, similar techniques to manufacture glassspheres are also known. These techniques employ a powdered glass with aglass composition comprising ranges of SiO₂ of 50-57%, R₂O of 2-15%,B₂O₃ of 0-20%, S of 0.05-1.5%, RO of 2-25%, R₂O₃ of 0-5%, and R₂O₅ of0-5%. From further yet art references, the use of an essentiallyborosilicate glass composition is known to manufacture glass sphereshaving an oxide range of SiO₂ of 60-90 wt %, an alkali metal oxide rangeof 2-20 wt %, a B₂O₃ range of 1-30 wt %, a sulfur range of 0.005 to 0.5wt %, and other conventional glass-forming ingredients.

A particulate solid feed material having an average particle size of upto 25 microns is introduced at the top of a heating chamber into a “wallfree” heated zone, according to a method known in the art for themanufacture of glass microspheres. The particles are transported to atleast one flame front by a carrier gas comprising a fuel gas and air.The carrier gases maintain the particles in a dispersive state while theparticles are heated to a temperature where at least partial fusionoccurs, while the agglomeration of particles during fusion is inhibited.The resulting spherical particles are cooled and separated from the gasstream by a hot cyclone.

Yet another process for producing hollow microspheres know in the artcomprises treating glass feed particles at a temperature above theworking temperature of the glass. The particles are suspended in agaseous current and passed through a burner for treatment. The particlesare rapidly heated to about 1500 to 1700° C. for a residence time ofless than about 0.1 seconds, and are cooled suddenly to below 750° C.The burner is operated such that the air factor, that is, the ratio ofthe amount of air introduced into the burner to the amount of airnecessary to produce a stoichiometric combustion, is between about 0.75and 1.1, or preferably 0.8-0.95. The particles are passed first througha reducing atmosphere and then through a non-reducing atmosphere.

Other known techniques for the manufacture of glass microspheres providefor a method in which feed material, in the form of solid glassparticles, is introduced near the bottom of a furnace into an ascendingcolumn of hot gases. The feed material is entrained in an upward movinghot gaseous stream. The residence time of the particles within thefurnace becomes a function of the mass of the particle, as the largerparticles ascend through the hot zone of the furnace more slowly thanthe small particles due to the force of gravity acting on the particles.As a result, the residence time of the particles in the furnace is indirect relationship to the heat requirements necessary to expand thesolid glass particles into hollow spheres.

Further technologies available in the art for manufacturing hollowmicrospheres employ a downward furnace suitable for heating discreteclay particles into hollow spherical particles. The particles are fedwith a vibrating feeder into a hopper of a burner from where they areentrained in a stream of gas and passed through a flame front inside thefurnace. The particles, in expanded state, are carried along with theflow of combustion gases and by gravity into a container. The containeris at a sufficient distance from the combustion zone to provide a coolerzone, and solidification of the particles occurs before the particleshit any hard surfaces or before encountering each other to avoidagglomeration. A ratio of air to natural gas of about 2:1.1 was found tobe suitable for raising the temperature of the particles to a range of1350° C. to 1500° C., and to create the hollow microspheres.

A low cost method of converting solid glass or ceramic micro-particlesinto hollow microspheres, is also known in the art, and consists offeeding the solid glass or ceramic micro-particles, along withpulverized coal, into a coal-burning boiler. According to the knownmethod coal-burning boilers generally produce micro-sized fusedparticles of ash, e.g. fly ash. A very small percentage of fly ashparticles (about 1% and less) may be hollow, and these particles arecommonly referred to as cenospheres. According to the known method theyield of hollow micro-particles is slightly increased by co-feeding flyor coal ash along with the pulverized coal.

Based at least on the above enumerated known methods and techniques, itis evident that there is still a need in the art for methods tomanufacture hollow glass microspheres that have the followingattributes:

-   -   high chemical durability in aqueous alkaline and acidic        environments;    -   high crushing strength;    -   high hydrostatic pressure rating;    -   high specific strength;    -   are an eco friendly product, able to utilize in their make-up        industrial waste byproducts, converting waste materials into        highly value added products; and    -   are produced by sustainable (energy efficient) methods via fast        manufacturing.

SUMMARY OF THE INVENTION

The present invention has been conceived and developed aiming to providesolutions to the above stated objective technical needs, as it will beevidenced in the following description.

In accordance with an embodiment of the present invention is proposed aglass microsphere comprising a plurality of glass walls, and a pluralityof hollow spaces, wherein said plurality of glass walls enclose at leastone of said plurality of hollow spaces, wherein said plurality of glasswalls comprise a second glass, wherein said second glass is formed byfurther processing a first glass melt, wherein said first glass melt isformed by melting a batch comprising a plurality of raw materials, andwherein the plurality of RAG components present in the first glass meltand a melt of the second glass is capable of providing at least one of aplurality of redox reactions and a plurality of events in the firstglass melt and the melt of the second glass, thereby creating the glassmicrosphere.

In accordance with further aspects of the present invention, the atleast one of the plurality of redox reactions is a non-equilibrium redoxreaction. The redox active group (RAG) components are incorporated atleast directly into the first glass melt, directly into said batch, andinto said batch and the first glass melt. The plurality of redox activegroup (RAG) components comprises redox active group components in atleast one of a gaseous form, a liquid form, a solid form, an aerosolform, and a combination thereof. The first glass melt comprises at leastone of a plurality of sulfide ions and a plurality of sulfate ions, aconcentration of the plurality of sulfide ions and a concentration ofthe plurality of sulfate ions comprised in the first glass melt beinggreater than zero. The first glass melt and the second glass comprise atleast one alkali metal oxide, and when sodium oxide is comprised by theat least one alkali metal oxide, a concentration of sodium oxide beingless than 4 wt % based on a mass of either the first glass melt and thesecond glass.

In accordance with another embodiment of the present invention isproposed a method of manufacturing a plurality of glass microspheres,comprising melting a batch into a first glass melt in a melter system,processing the first glass melt into a second glass, pulverizing thesecond glass into a plurality of glass fragments, thermally processingthe plurality of glass fragments into a plurality of glass microspheres,providing at least one of a plurality of redox reactions and a pluralityof events in at least one of the first glass melt and a melt of saidsecond glass, wherein at least one of the redox reactions and theplurality of events are induced by a plurality of redox active group(RAG) components.

In accordance with a further yet embodiments of the present invention,the plurality of redox active group (RAG) components comprises redoxactive group components in at least one of a gaseous form, a liquidform, a solid form, an aerosol form, and a combination thereof. Themethod further comprises incorporating the redox active group (RAG)components into at least one of the batch, and the first glass meltwhile the first glass melt is inside a melter system, and into saidbatch and the first glass melt, the incorporating step being performedby at least one of blending, bubbling, injection, spraying, dipping, andstirring. The batch comprises at least one recovered material. Themelter system comprises at least one of a glass-melting zone, a glassmelt processing zone, and a glass melt discharge zone. The methodfurther comprises incorporating the plurality of redox active group(RAG) components inside either one of the first glass melting zone, theprocessing zone, and the discharge zone of the melter system. A totalresidence time of the first glass melt in the melter system during themelting step is less than 12 hours. The batch comprises either one of aplurality of raw materials, the plurality of redox active groupcomponents and a combination thereof. Thermally processing saidplurality of glass fragments comprises expanding said plurality of glassfragments by a plurality of gases generated via at least one of saidplurality of redox reactions induced by said plurality of redox activegroup components. At least one of the plurality of redox reactions is anon-equilibrium redox reaction. The first glass melt comprises at leastone of a plurality of sulfide ions and a plurality of sulfate ions, aconcentration of the plurality of sulfide ions and a concentration ofthe plurality of sulfate ions comprised in the first glass melt beinggreater than zero. The first glass melt and the second glass comprise atleast one alkali metal oxide, and when sodium oxide is comprised by theat least one of the alkali metal oxides, a concentration of the sodiumoxide is less than 4 wt % based on a mass of either the first glass meltand said second glass. The plurality of redox active group (RAG)components comprises at least one of a plurality of redox active groupreactants, and a plurality of redox group reaction products.

In accordance with another embodiment of the present invention isproposed a composite product comprising a combination of the pluralityof glass microspheres manufactured according to the various embodimentsof the present invention, and at least one of a plurality of polymermatrices, a plurality of cementiteous matrices, a plurality of fluidmatrices, a plurality of solid matrices, a plurality of fiber containingmatrices, and a plurality of metal matrices.

The methods of the present invention are found to produce superiorhollow glass microspheres of superior strength, able to withstand highhydrostatic pressures, versus the hollow glass bubbles manufactured bythe process of simultaneous fusion of raw materials into glass at thetime of expansion.

Since residence times are relatively short at the high temperaturesrequired by the processing steps of melting and thermal processing ofthe present invention, the embodiments of the present invention alsoprovide high energy efficiency in addition to the high throughputattributes. Considering the low cost of the recovered materials that arebeing utilized as the raw materials in the batch, the present inventionprovides viable economics together with environmentally friendlypractices to manufacture high quality glass microspheres.

More detailed explanations regarding these and other aspects andadvantages of the invention are provided herewith in connection with theexemplary embodiments of the present invention.

BRIEF DESCRIPTION OF DRAWINGS

The above and other aspects, features and advantages of the presentinvention will become more apparent from the subsequent descriptionthereof, presented in conjunction with the following drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a method for manufacturinga plurality of glass microspheres in accordance with the presentinvention;

FIG. 2 comprises representation of a glass microsphere; and

FIG. 3 is a schematic representation of a glass melter system inaccordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following description of the presently contemplated best mode ofpracticing the invention is not to be taken in a limiting sense, but ismade merely for the purpose of describing the general principles of theinvention. The scope of the invention should be determined withreference to the claims.

Reference will now be made to the drawings wherein like numerals referto like parts throughout. As described herein below, the embodiments ofthe present invention provide a plurality of chemically durable,synthetic glass microspheres having properties and characteristicssimilar or superior to the cenospheres derived from coal combustion, andsynthetic microspheres manufactured in accordance with other methodsknown in the art. The preferred embodiments also provide a method formanufacturing the plurality of glass microspheres, including compositionand processing, and uses for the microspheres in various applications,including as functional fillers in various composite materials, inapplications related to oil and gas industry, such as proppants forhydraulic fracturing or hydrofracturing fluids, well casing cement,drilling fluids, and in constructions materials.

The glass microspheres manufactured according to an embodiment of thepresent invention comprises a single or a plurality of glass walls, anda single or a plurality of voids or hollow spaces defined and enclosedby said wall or walls. The terms of “glass microspheres”, “syntheticglass microspheres”, and “hollow glass microspheres” are interchangeablyused throughout this document to refer to a structure that comprises aplurality of enclosure glass walls, surrounding at least one or aplurality of hollow spaces.

The synthetic glass microsphere as described herein generally comprisesa substantially spherical outer wall and a substantially enclosed cavityor void defined by the wall, resembling the general configuration ofharvested cenospheres from coal burning fly ash. All these structuralaspects of the glass microsphere will be described in more detail inthis document with reference to FIG. 2. In certain preferredembodiments, the synthetic glass microsphere has one or more of thefollowing characteristics:

-   an aspect ratio of between about 0.8 and 1;-   a void volume of between about 10 and 95%, based on the total volume    of the microsphere;-   an outer wall thickness of approximately 2 and 55% of the    microsphere radius;-   a composition comprising in weight percent: about 30 to 85% SiO₂,    about 2 to 30% Al₂O₃, 2 to 30% divalent metal oxides selected from    the group of MgO, CaO, SrO, BaO, about 4 to 12% monovalent metal    oxides selected from the group of Li₂O, Na₂O, K₂O, Cs₂O, and 2 to    30% of other metal oxides and chemical species, including    multivalent metal oxides which exist in multiple oxidation states    such as Fe₂O₃, and chemical species such as borates, phosphates,    sulfates, etc;-   a silica to alumina ratio of greater than about 1 (mole ratio);-   an average diameter of between about 5 and 1000 microns; and-   a particle density (e.g. apparent density) of between about 0.1 and    2.2 g/cm³.-   Further structural and functional details will be provided in this    document in connection with the glass microsphere while referring to    the illustration made in the drawings.

As will be described in greater detail below, the synthetic glassmicrosphere of certain preferred embodiments of the present inventioncan be formed by performing a method of manufacturing a plurality ofglass microspheres, comprising melting a batch into a first glass meltin a melter system, processing the first glass melt into a second glass,pulverizing the second glass into a plurality of glass fragments,thermally processing the plurality of silicate glass fragments toconvert the plurality of glass fragments into a plurality of glassmicrospheres, providing a plurality of redox reactions and a pluralityof events in at least one of the first glass melt and a melt of thesecond glass, the plurality of redox reactions and the plurality ofevents being induced by a plurality of redox active group components andtheir reaction products. It is of note that for simplicity ofdescription in the rest of this document said redox active groupcomponents and their reaction products will be referred to simply as“RAG components”.

According to one aspect of the present invention, non-equilibrium redoxreactions are generated in the first glass melt, and the second glassmelt by the RAG components.

The RAG components are components comprising at least one of reducing,neutral, and oxidizing species. The RAG components in combination withglass forming raw materials form a batch that is melted to provide aglass precursor from which a plurality of silicate glass fragments (SGF)are made. Throughout this document, the terms of redox active silicateglass fragments, silicate glass fragments, SGF and plurality of glassfragments are interchangeably used, whilst they all indicate the sameglass fragments. According to an embodiment of the invention, the glassforming raw materials may be silicate glass forming raw materials thatare melted to provide a first glass melt, a silicate glass precursor(SGP).

According to the present invention, the RAG components are one ofintrinsic, extrinsic or a combination thereof, to the constituents thatmake up the raw materials batch. The composition of the RAG componentsis selected such to provide and/or influence a plurality of redoxreactions and/or physical events to take place within the first glassmelt of said raw materials. The RAG components and/or their reactionproducts formed and/or incorporated in the first glass melt are carriedover to a second glass, and further provide and/or influence a pluralityof redox reactions and/or physical events that take place within thesecond glass during the reheating, melting, and the expansion of thesecond glass, leading to the formation of hollow glass microspheres.

In accordance with an embodiment of the present invention the pluralityof redox reactions and/or physical events may not be allowed to reachtheir final equilibrium state and may be intentionally terminated undera predetermined non or quasi-equilibrium state. Such a redox reaction istermed a “non-equilibrium redox reaction” throughout the presentdocument.

In the present document the terms “non-equilibrium phenomena”,“non-equilibrium chemical reactions” and “non-equilibrium redoxreactions” are used interchangeably and are intended to be associated atleast the meaning provided above, as a plurality of redox reactions thatare not allowed to reach their final equilibrium states and may beintentionally terminated under a predetermined non or quasi-equilibriumstate or may be terminated due to changes in the conditions to which thereactants are exposed to during the reaction. For example, by rapidlycooling the first glass melt below its softening temperature, as ithappens by discharging the first glass melt from a melter, or byquenching the first glass melt in air, the plurality of redox reactionsand/or physical events taking place in the glass are intentionallyterminated (forced to terminate).

In addition, the non-equilibrium phenomena is understood in accordancewith an embodiment of the present invention as including chemical andphysical events such as chemical reactions, redox changes, and changesin the physical properties of the first and second glass melts, such aschanges in solubilities of certain gases or vapors in the glass melts asa function of temperature.

In accordance with a particular embodiment of the present invention,non-equilibrium redox reactions are achieved by selecting thecomposition of the redox active group RAG components such that it isadapted specifically for a specific first glass composition. For anygiven first glass composition, an optimum composition of the RAGcomponents is selected from a range, to encompass the processingtemperatures and atmosphere that shall be selected in order to optimizethe non-equilibrium redox reactions under a prescribed set of reactionsand/or events, specifically with respect to time and/or temperature.These aspects of the invention, especially insofar as the modes ofrealization of the non-equilibrium redox reactions and the reactiondynamics that are envisioned in accordance with the various embodimentsof the present invention, are disclosed in detail in the reminder ofthis document.

From the perspective of redox reaction dynamics, redox reactions areseparated at least operationally, into redox reactions, andnon-equilibrium redox reactions.

By “redox reaction” is understood a reaction that is allowed to proceedfrom reactants to final reaction products without any externalinterruption, until the reactants are substantially depleted or becomenon-reacting. In contrast, the “non-equilibrium redox reactions” arereactions that are induced to proceed, but are intentionally ceased at apredetermined stage during the reaction. The predetermined stage isdetermined by the reaction time and/or reaction temperature and/orreaction dynamics, and as a result, both reactants and reaction productsco-exist in the resulting glass melt. By triggering a ceased/dormantnon-equilibrium redox reaction, the reaction may take a different pathand/or rate to proceed, thus leading to a set of different products thanotherwise would not have been possible if the reaction would havecontinued on its initial reaction path and/or with its originallyintended rate. In order to redirect a non-equilibrium reaction to take adifferent path or assume different dynamics to completion, certainreaction parameters may be altered/changed from the initial/originalreaction parameters. The parameters comprise one or a combination ofambient conditions, pre-treatments, incorporation of redox active groupcomponents, reaction temperature, heating rate, the redox state of theglass melt, the physical size of glass fragments, etc.

In accordance with an embodiment of the present invention, theconstituents of the redox active group RAG components comprise aplurality of redox capable materials that either themselves and/or theirreaction products can change the oxidation states in the first glassmelt, and in the second glass melt based on a predetermined set ofparameters. The changes in the oxidation states and/or the solubilitiesof the RAG components (including reaction products) result in theformation and evolution of gas in the second glass, leading to theformation of the hollow glass microspheres. In addition, a reduction ofthe melting temperature and/or viscosity of the second glass as comparedto the first glass is realized as well.

Exemplarily, the plurality of redox active group components inaccordance with the present invention include the chemical species ofcarbon containing, sulfur containing, selenium containing, oxygencontaining, hydrogen containing, nitrogen containing, phosphorouscontaining, and multivalent metals containing materials. In accordancewith a preferred embodiment of the present invention, the RAG componentsare redox capable materials comprising such materials as bonded and/ornon-bonded carbon, hydrogen, nitrogen, and chemical species such assulfates, sulfides, nitrides, nitrates, selenites, selenides, andcompounds from the group of multivalent metals, and transition metalssuch as: tin, antimony, iron, copper, zinc, manganese, niobium, andvanadium. Advantageously, the majority of these materials haverelatively low cost, and some of them already exist as impurities inmany industrial wastes and byproducts. The plurality of RAG componentscomprises at least one electron donor and at least one electronacceptor.

In accordance with one embodiment of the invention, either pre- and postindustrial, and consumer byproducts (also referred to generally as“recovered materials” throughout this document) are utilized as rawmaterials as part of the batch, in combination with the RAG componentsto be melted in a first glass. In accordance with an embodiment of theinvention, the entirety or the majority of the quantity of the pluralityof the RAG components may exist intrinsically in the recovered materialsfrom which a batch is prepared and which is subsequently melted to formthe first glass. As a result, only a portion of, and no additional RAGcomponents are needed to supply the total amount of RAG componentsrequired to provide at least one of the plurality of the non-equilibriumredox reactions and the plurality of events to take place in theresulting first glass melt, and the second glass melt that lead to thecreation of the glass microsphere.

However, in the absence of all or of a part of the necessary quantity ofRAG components in the starting raw materials in the batch, further RAGcomponents are added either to the batch prior to melting the batch intoa first glass melt, or during the melting of the first glass, or uponprocessing the first glass melt while in a melter system, or upondischarging the first glass melt from the melter system. Said pluralityof redox active group components are added into the first glass melteither inside or outside the melting zone of the melting system. As itwill become apparent later in this document, the function of the RAGcomponents is at least to produce gas in the melt of the second glassand to lower the melting temperature of the second glass as compared tothe melting temperature of the first glass.

The non-equilibrium redox reactions of the present invention are timeand temperature dependent, in addition to exhibiting potentialdependencies on other parameters, such as the characteristics of theirsurrounding environment and atmosphere.

As described above, preferred embodiments of the present invention alsoprovide methods of manufacturing a plurality of glass microspheres.Referring now to FIG. 1, FIG. 1 is a block diagram of an embodiment of amethod of manufacturing a plurality of microspheres, in accordance withthe present invention. The method is denoted with 100 in FIG. 1.

It is to be understood that a plurality of other variations from theembodiments of the present invention presented herein will be apparentto a person skilled in the art. Said plurality of other variations is aswell considered to be comprised within the scope of the presentinvention.

In accordance with an embodiment of the present invention, the method100 of manufacturing a plurality of glass microspheres comprises thesteps described in the following.

In accordance with a first step of method 100, in accordance with oneembodiment of the present invention, a plurality of silicate glassprecursor (SGP) raw materials 202 are combined with a plurality of redoxactive group (RAG) components 204. Exemplarily, the materials 202 andthe components 204 may be combined by blending in step 102, to form acombination or a batch 200. In the following the terms “combination ofthe plurality of silicate glass precursor (SGP) raw materials andplurality of redox active group (RAG) components” and the terms “batch”or “combination” with be used interchangeably and employed as having thesame meaning.

Exemplarily the plurality of silicate glass precursor (SGP) rawmaterials 202 comprise at least one or a combination of glass rawmaterials. Such glass raw materials are known to a person skilled in theart of glass making. Alternatively, materials 202 are made entirely orin part from a plurality of materials selected from a group comprising asilicate containing material, an aluminosilicate containing material, aborosilicate containing material, a lime silicate containing material,an incineration ash, a slag, coal ash, bottom ash, an asbestoscontaining waste material, an incineration ash/residue, a municipalwaste material, a hazardous waste material, a radioactive wastematerial, and a medical waste material. All of the above enumeratedmaterials 202 may be recovered materials. It is to be understood thatthe above mentioned materials 202 are only exemplary and theirenumeration is not exhaustive. Any other materials apparent for theperson skilled in the art are considered to be included within the scopeof the present invention.

In accordance with another exemplary embodiment of the presentinvention, the plurality of silicate precursor (SGP) raw materials 202may also include glass forming oxides, intermediate glass formingoxides, and glass modifier oxides. Exemplarily, the glass forming oxidesare silica, phosphorous oxide, and boron oxide. Exemplarily,intermediate glass forming oxides are alumina, zirconia, titania, ferriciron. Exemplarily, the glass modifier oxides are oxides of calcium,magnesium, zinc, ferrous iron, and alkali metals. Again, any other glassforming oxides, intermediate glass forming oxides and glass modifieroxides apparent to a person skilled in the art are considered to bewithin the scope of the present invention.

In accordance with a further exemplary embodiment of the presentinvention the plurality of silicate glass precursor (SGP) raw materials202 comprises non-waste raw materials, such as silica, siliceousmaterial, alumina, alumina silicate materials, boron oxide,borosilicates, calcium silicates, aluminates, alumina bearing materials,lime and magnesium bearing materials such as limestone and dolomite, andalkaline oxide bearing compounds and minerals such as phosphates,carbonates and hydroxides of alkali metals. The above enumeration is notexhaustive and any other materials apparent for the person skilled inthe art are considered to be included within the scope of the presentinvention.

According to yet another embodiment of the present invention, theplurality of silicate glass precursor (SGP) raw materials 202 mayconsist entirely or partially of waste materials or byproducts. Thesematerials are used in combination with the plurality of redox active(RAG) components 204 to prepare the batch 200, and subsequently thefirst glass melt 206. In a particular embodiment of the presentinvention, a recycled waste material or byproduct may already be in avitrified form. In addition, the vitrified waste material mayintrinsically comprise the required concentration and types of the RAGcomponents 204. In such case, the vitrified waste material is treated asthe first glass 206. On the other hand, if there was not a sufficientconcentration and types of the RAG components intrinsically present in avitrified waste material, then the necessary amount of RAG components204 is combined with that particular vitrified waste material in thebatch 200 before proceeding to prepare the first glass melt 206. Thereference to “sufficient” amounts in this document will be expanded uponin more detail while discussing specific examples. It is intended thatthe amounts and the types of the RAG components be present in amountsthat lead to: producing enough gas for making hollow-microspheres, andto lowering the melting temperature of the second glass. The secondglass and the hollow microspheres will be described later in thisdocument at least in connection with the illustration of FIGS. 1 and 2.

Exemplarily, the recycled waste materials and byproducts are at leastone of fly ash, bottom ash, incineration ash, waste glasses, blastfurnace slag, alumina silicate containing materials, vitrified asbestoswaste material, vitrified hazardous waste materials, vitrifiedradioactive waste materials, spent inorganic catalysts, red mud, kilndust, spent oil shale, and residual biomass.

The recovered waste byproducts 202 may be selected from at least one ormore of a silicate material, an aluminosilicate material, a borosilicatematerial, coal ash, bottom ash, slag, waste glass, an alumina containingmaterial, a titania containing material, a zirconia containing material,a vitrified asbestos containing material, a vitrified hazardous wastematerial, a vitrified gamma emitting nuclear waste material, a biomasscontaining material, etc.

The compositional range of the silicate glass precursor SGP rawmaterials 202 is dependent on the target glass composition for the firstglass 206, and consequently the target composition of the second glass208. In addition, the amount of each candidate raw material enteringinto the SGP raw materials mix depends on the constituents of the RAGcomponents. For example, gypsum (CaSO₄.2H₂O) supplies sulfate ions as apart of the RAG components, and calcium ions that become a part of thefirst glass. The chemical composition of the batch 200 is morerepresentative of the first glass 206, excluding the volatiles (e.g.water vapor), and the RAG components 204.

The SGP raw materials 202, in accordance with another embodiment of thepresent invention, are substantially free of any redox active components204. In accordance with yet another embodiment of the present invention,the SGP raw materials 202 include all or a portion of the redox activecomponents 204 intrinsically in their make up.

In accordance with the present invention, several distinct embodimentsare envisioned: A first embodiment when the SGP raw materials 202already intrinsically comprise a sufficient amount of RAG components204. In this case, no further RAG components are added to the batch 200.A second embodiment wherein the SGP raw materials 202 already compriseintrinsically RAG components 204, but not in sufficient amounts. In thiscase the balance of the RAG components 204 are added to batch 200. In athird embodiment the SGP raw materials 202 are practically devoid of theRAG components 204. In this case, like the previous case, the RAGcomponents 204 are added to the batch 200. In all the three embodimentslisted above, additional RAG components may be added to the first glassmelt 206 to adjust parameters such as rate, termination, reactionproducts, etc. of the redox reactions. Other modalities of providing RAGcomponents 204 to the raw materials 202 may be apparent to the skilledperson aiming to practice the present invention. All said modalities arecomprised within the scope of the present invention. Further in thisdocument will be shown an embodiment of the invention wherein theaddition of the RAG components 204 to the first glass melt 206 takesplace either exclusively or in combination with addition of the RAGcomponents to the SGP raw materials 202 via batch 200 and melting of thebatch 200 to the first glass melt 206.

The RAG components 204 according to one embodiment of the invention arein the form of oxides, hydroxides, anions, metals, cations, chemicalspecies, chemical compounds, elements, or a combination thereof.

In accordance with one exemplary embodiment of the present invention,the RAG components 204 may comprise one or a combination of compounds orspecies containing sulfur, carbon, oxygen, nitrogen, hydrogen,phosphorous, a multivalent metal such as a multivalent transition metal.The sulfur containing material(s) is selected from at least one ofsulfates, sulfites, sulfides, and elemental sulfur. Alternatively, inaccordance with another embodiment of the present invention, the RAGcomponents 204 comprises at least one or more of sulfur containingmaterial(s), carbonaceous material(s), and iron containing material(s),in addition to other appropriate redoxable materials, chemical species,and chemical compounds.

In accordance with another embodiment of the invention, at least aportion of the requested RAG components 204 are an integral part of therecovered waste byproduct(s). Alternatively, the RAG components 204 arecomprised in additives added to batch 200 in addition to the rawmaterials 202 and the RAG components 204, or the RAG components 204 maybe separately added to the batch 200 prior to vitrification of the batchinto a first glass 206. The RAG components 204 may also be added duringthe melting of the first glass, and/or after the melting of the firstglass 206, in the various zones of the melter system.

The step 102 of method 100, the combination step or the blending step ofraw materials 202 with RAG components 204 is carried out in a blendersuch as a V-blender, a mill, a homogenizer, and in any otherconventional and non-conventional mixers and blenders.

The RAG components 204 are in one of a solid, a liquid, a gaseous form,an aerosol form or a combination thereof. In accordance to oneembodiment of the invention, the gaseous RAG components 204 comprise atleast one of air, oxygen, nitrogen, hydrogen, steam, hydrocarbons,gaseous organics, CO₂, CO, H₂O (liquid and/or vapor and/or steam), SO₂,SO₃, H₂S, NH₃, and a combination thereof. In another embodiment of theinvention, the RAG components 204 are solids in the form of fine powdersand solid aerosol. For example, carbon in form of coke, coal, or finegraphite powder in a gas carrier stream or liquid carrier stream isinjected into the first glass melt 206 formed by melting the batch 200to trigger a rapid redox reaction, such as reduction of sulfates, andmultivalent metal oxides.

In accordance with the embodiment of the invention wherein thepresentation of the RAG components 204 is in liquid form, the injectableliquid RAG components 204 are for example one of liquid water, peroxide,a soluble sulfate or sulfuric acid, liquid fuels, liquid oils, andliquid hydrocarbons. Said liquid RAG components 204 may be injected intothe plurality of silicate glass precursor (SGP) raw materials 202, thebatch 200, and the first glass melt 206 at various locations in themelter, such as a secondary melt chamber, a glass-refining chamber andthe discharge chamber of the melter system. Solid form RAG components204 may include iron bearing minerals and oxides, and sulfur bearingcompounds and minerals such as gypsum, salt cake, sulfides, andcarbonaceous materials, such as carbon, or a carbon containingmaterial(s).

The RAG components 204 are elected such to trigger non-equilibrium redoxreactions, such as oxidizing and reducing reactions.

In accordance with a preferred embodiment of the invention, the RAGcomponents 204 included in the batch 200 are solids and comprisesulfates, transition metal oxides and compounds, and carbonaceousmaterials. Sulfates also include sulfites. In accordance with anotherpreferred embodiment of the invention, the gaseous and/or aerosol formof RAG components 204 may be optionally purged/bubbled inside the firstglass melt 206. Alternatively, the RAG components 204 are included inthe first glass melt 206 by at least one injection, spraying, dipping,and stirring, or a combination thereof.

The gaseous RAG components 204 are added to the first glass melt aloneor in combination with one or more of solids, liquids, and other gasesthat include SO₃, SO₂, H₂S, H₂, N, CO₂/CO, H₂O, O₂, hydrocarbons, NH₃,NO_(x), air, and various organic gases. All the gaseous RAG components204 may be purged or bubbled inside the first glass melt 206.

According to the present invention, the concentrations of several RAGcomponents 204 in the batch 200 based on the weight percentage of thecomponent over the dry mass of the batch 200 are as follows:sulfates/sulfites calculated as SO₄ ⁻² is from 0.1 to 5%, sulfides andsulfur calculated as S⁻² from 0 to 2%, carbonaceous materials calculatedas elemental carbon, from 0 to 3%, multivalent and/or transition metalscalculated as metal oxides, from 0.1 to 25%, andnitrates/nitrites/nitrides calculated as N from 0 to 2%.

In accordance with one embodiment of the present invention, thecompositional range of the first glass 206 in weight percentage fallswithin: 30-85% SiO₂, 4-12% of R₂O (R₂O is one or combination of Li₂O,Na₂O, K₂O), 2-30% Al₂O₃, 2-30% RO (RO is one or a combination of MgO,CaO, SrO, BaO), and 0-30% of other oxides and chemical species such asB₂O₃, TiO₂, etc.

The type and the amount of RAG components 204 elected to be combined,exemplarily via blending in a given batch 200, is based on the chemicalcomposition of the SGP raw materials 202, and the redox reactionsdesired to be induced, which collectively will determine the specificphysical and chemical properties of the glass microspheres created bypracticing the method of the present invention. As previously mentioned,the RAG components 204 may be intrinsic to the SGP raw materials 202, ormay be blended as partial or as completely separate entities with theSGP raw materials 202, prior or during the step 104 of method 100 ofmelting the batch 200 into the first glass melt 206.

According to the present invention, the RAG components 204 are capableto provide non-equilibrium redox reactions in the first glass melt 206,as it will be described in more detail further in this document.

According to the present invention, the plurality of RAG components 204are capable to go through redox reactions and/or events in the first andsecond glass melts 206 and 208. By redox reactions are understoodreduction-oxidation reactions. The redox reactions generally comprisechemical reactions, and the events comprise reversible and irreversiblechemical reactions, and physical changes/events such as thermal reboil,and sublimation. During the occurrence of the redox reactions in thefirst and second glass melts 206 and 208, the RAG components 204 changetheir corresponding oxidation states of their ions/chemical species.

The redox reactions envisioned to occur in accordance with the presentinvention are at least one of an oxidation reaction, a reductionreaction, and a combination thereof. As such, a series of electrontransfers take place between the constituents of the RAG components 204,that are elements, molecules, ions, and chemical species. The oxidationis associated with the loss of electrons resulting in an increase inoxidation state, and the reduction is associated with the gain ofelectrons resulting in a decrease in oxidation state by either one or aplurality of atoms, molecules, ions, and chemical species of thecorresponding RAG component 204.

In addition to the SGP raw materials 202, and the RAG components 204,other additives may be added to constitute a combined batch 200. Theadditives may comprise a variety of recovered materials, and variouschemical compounds, and chemical species that become a part of the batch200 and therefore a part of the first glass 206. The additives are addedto achieve the targeted composition of the first glass melt 206.

According to one embodiment of the present invention, the batch 200 mayinclude various recovered waste byproduct(s), and a plurality ofadditives and/or glass additives. The plurality of additives and/orglass additives in addition to other chemical compounds, and chemicalspecies may comprise one or more of the following compounds: silica,siliceous materials, aluminosilicate materials, alkaline earth metalcontaining materials, alkali metal containing materials,phosphate-containing materials, boron-containing materials, and acombination thereof.

In accordance with various embodiments of the invention the RAGcomponents 204 are an integral part of either one or both the recoveredwaste byproduct(s), and the additives, or are externally added to thebatch 200 prior to or during the vitrification of the batch 200 into thefirst glass melt 206, or are added directly to the first glass melt 206,or to a combination thereof.

Exemplarily, when a recovered waste byproduct, such as type C fly ash isused as the primary source for the SGP raw materials 202 a siliceousadditive with high silica content is blended in batch 200 to increasethe silica content of the first glass 206. Examples of such siliceoussources are ground silica sand, silica flour, diatomaceous earth, andground quartz. In general, the majority of additives comprise one ormore of glass formers, glass intermediate oxides, and glass modifiers.For examples, some common additives are materials that contain one ormore of boron oxide, phosphorous oxide, titania, alumina, alkali metaloxides, and alkaline earth metal oxides.

As it will be disclosed in detail in the following portions of thisdocument, with the means and methods of the present invention it ispossible to manufacture glass microspheres 212 from SGP raw materials202 having low alkali metal oxide content, of equal to less than 12 wt %of total alkali metal oxides on mass basis of the resulting first glass206. In one preferred embodiment of the present invention, in order toprovide a limit for the alkali content of the SGP raw materials 202,when sodium oxide is at least one of the alkali metal oxides, theconcentration of sodium oxide in the first glass 206, and consequentlyas well in the second glass 208, should be below 8 wt %, and preferablyless than 4 wt % based on a mass of either the first glass melt and thesecond glass. As a result the glass microspheres 212 manufactured fromsaid SGP raw materials 202 will have exceptionally high chemicaldurability, as indicated by their very low leach rates in aqueousalkaline environments.

One way to determine the chemical durability of the glass microspheres212 provided via the means and methods of the present invention, is byemploying the test prescribed by standard ASTM C1285-02, referred to asthe “product consistency test (PCT) test”. An acceptable PCT test resultin accordance with the present invention is a composite leach rate thatis less than 500 g/m²·day (e.g. g/m² per day) at a pH of about 11, and atemperature of about 90° C. A preferred composite leach rate is lessthan 100 g/m²·day under the same test conditions mentioned above,averaged over test duration of 3 days.

An alternative criteria to determine the suitability of the glassmicrospheres 212 with respect to the chemical durability is based on acomparative leach test, that benchmarks the glass microspheres of thepresent invention against cenospheres that are harvested from fly ash, acoal combustion byproduct. Under a suitable comparative test protocol,the microspheres created by employing the means and methods of thepresent invention are tested under identical conditions side by sidewith the cenospheres. For example, in one aspect of the presentinvention, an acceptable comparative chemical durability test result forthe microspheres 212, reported in terms of leach rate, is not more than20% above the leach rate obtained under the identical conditions for thecenospheres.

In accordance with a second step of method 100, in accordance with oneembodiment of the present invention, the batch 200 resulting from thecombination step 102 is melted in a step 104 in a melter system. Theresult of said melting step 104 is the first glass melt 206.

The step 104, of melting of the batch 200 into the first glass melt 206is carried out in a glass melter system under a variety of conditionselected depending on the redox state desired to be obtained in the firstglass melt 206. The variety of conditions are controlled via controllingparameters, that for the melting of batch 200 are one of meltingtemperature, melting time, melting dynamics, such as stirring/agitation,and the melt redox state. The melt redox state is controlledintrinsically by non-equilibrium redox reactions, and extrinsically bymelting either under one of reducing, neutral or oxidizing conditions.The extrinsic conditions apply to both the ambient and the melt poolenvironments where the glass melting is taking place.

Details regarding what constitutes a glass melter appropriatelyconfigured to fulfill the requirements mentioned above will be disclosedin the subsequent sections of this document. Further, known, and unknowndetails regarding melter configuration, envisioned by a person skilledin the art of melter design and not mentioned expressly but suggestedand or hinted to in this document are as well considered to constitute apart of the present invention.

The redox reactions that the RAG components 204 are going through withinthe first glass melt 206 and the second glass 208 have the combinedeffects of lowering the melting temperature of the second glass melt 208to a temperature that is lower than the melting temperature of the firstglass melt 206, while at the same time producing a volume of gas that isemployed to manufacture the plurality of hollow glass microspheres 212from the second glass 208. It shall be understood that the RAGcomponents 204 in accordance with the present invention include both thereactants and the reaction products of the RAG components. In oneembodiment of the present invention, the “glass-flow point temperature”of the second glass melt 208 is lowered as the result of the occurrenceof the redox reactions provided by the RAG components 204. This loweringis measured as compared to the glass flow-point temperature of the firstglass melt 206. By definition, the glass viscosity at the glass-flowpoint temperature is about 10⁵ poise. In another embodiment, the meltingtemperature of the second glass melt 208 is lowered as the result of theoccurrence of the redox reactions provided by the RAG components 204 ascompared to the melting temperature of the first glass melt 206. In yetanother embodiment, according to the present invention the “glassworking-point temperature” of the second glass melt 208 is lowered asthe result of occurrence of the redox reactions provided by the RAGcomponents 204 as compared to the glass working-point temperature of thefirst glass melt 206. By definition, the glass viscosity at the glassworking-point temperature is about 10⁴ poise.

In accordance with the present invention, the melting temperature of thesecond glass 208, is dependent on the concentration of ferrous iron inthe second glass 208. For a given concentration of total iron in theforms of ferric and ferrous iron in the second glass 208, more ferrousiron corresponds to a lower melting temperature of the second glass 208.In a general scheme, more ferrous iron corresponds to a more reducedsecond glass 208. In contrast, more ferric iron corresponds to a moreoxidized second glass 208. Depending on the redox state of the secondglass 208 as being either oxidized, or reduced, there is a temperaturedifference of at least 10° C., preferably 40° C., and most preferably80° C., between the melting temperatures of oxidized and reduced formsof the second glass 208.

Exemplarily, according to one embodiment of the present invention, thefirst glass 206 is melted under oxidizing conditions as dictated by themelting parameters and/or the melter requirements and/or limitations.For example, the electrodes in the melting zone of the melter systemwill last longer in contact with an oxidized glass as opposed to asituation when they are in contact with a reduced glass. The redox stateof the first glass melt 206 can be changed in the melter system viadirect incorporation of the RAG components 204 into the first glass melt206, as will be disclosed further in more detail. In the melter system,reducing RAG components in gaseous or aerosols forms are brought incontact with the first glass melt 206 in a processing zone of the meltersystem, or in a discharge zone outside the melting chamber. The contactis made by injecting, purging, or bubbling the RAG components 204 in theform of gas and/or aerosol into the first glass melt 206.

As previously mentioned in this document the RAG components 204,according to the invention, are in the form of solids, liquids, gases,aerosols, and comprise oxides, hydroxides, anions, cations, chemicalcompounds, chemical species, elements, or a combination thereof. The RAGcomponents 204 are capable of providing at least one non-equilibriumredox reaction in either one or both the first glass melt 206, and thesecond glass melt 208.

As it is described in detail in this document, according to oneembodiment of the present invention, a plurality of glass microspheres212 are manufactured from the batch 200 that comprises at least one of aplurality of silicate glass precursor raw materials 202 and at least aplurality of RAG components 204. The RAG components 204 included in thebatch 200 undergo redox reactions while in the melter system whileforming the first glass melt 206, and as such, the RAG componentsreaction products are created in the first glass melt 206.

A composition of the SGP raw material 202 according to one embodiment ofthe present invention, is preferably an alumina silicate basedcomposition. A glass created from an alumina silicate based SGP rawmaterial 202 exhibits high chemical durability in alkaline environments,and is suitable for forming thin partition walls or envelopes,surrounding the gas bubbles within glass microspheres 212. As such, theglass microspheres 212 are capable of withstanding high isostaticpressures of well over 1000 psi. Various additives, such as glassformers and glass modifiers may be added to the alumina silicate basedSGP raw material 202 to impart specific properties. For example, in onepossible embodiment, boron oxide is added as a glass former to extendthe glass forming temperature range and to reduce the divitrificationpotential of the first and second glass melts 206 and 208. Thecomposition of the second glass 208, for applications wherein the hollowglass microspheres 212 are to be exposed to high alkaline environment,needs to be highly chemically durable. For this reason in accordancewith one embodiment of the present invention, the first glass 206, andconsequently the second glass 208 comprise low concentrations of alkalimetal oxides, and moderate to high concentrations of alumina, andalkaline earth metal oxides.

As it was previously mentioned, according to one aspect of the presentinvention, the SGP raw materials 202 comprise raw materials that arenon-waste materials, and are considered ordinary glass raw materials.These SGP raw materials 202 are combined with the corresponding RAGcomponents 204 to form the batch 200. As an alternative, the SGP rawmaterials 202 comprise and may be melted in step 104 from a combinationof recovered materials, and non-waste raw materials. Exemplarily of therecovered materials are blast furnace slag, fly ash, bottom ash, red mudfrom aluminum smelting processes, kiln dust, spent oil shale, minetailings, and spent catalysts.

The SGP raw materials 202 may be combined with the RAG components 204 ina melted or a non-melted state. In the embodiment of the invention wherethe SGP raw materials 202 are in a non-melted state, the RAG components204 may all be added to the batch 200 prior to melting the SGP rawmaterials, or optionally they may be added during or after the meltingof the SGP raw materials 202. As discussed above, the RAG components 204may include one or a combination of solids, liquids, gases, vapors,aerosols that are introduced and incorporated into the first glass melt206 during one or a combination of melting, processing the melt,conditioning the melt, refining the melt, and discharging processes,collectively referred to “while in the melter system”. The introductionand/or incorporation of the RAG components 204 into the first glass 206while in the melter system is carried out by blending, stirring,injecting, bubbling, mixing, spraying, dipping or a combination thereof.Other technique of incorporating the RAG components 204 into the firstglass melt 206 while in the melter system used by a person skilled inthe art are within the scope of the present invention.

Feeding and melting the batch 200 into a glass melter system are carriedout in one or a combination of a batch method, a semi-continuous method,and a continuous method. The glass melter envisioned in accordance withthe present invention is selected from one or a combination of a fuelfired glass melter, an electric glass melter, a plasma-torch glassmelter, an inductively coupled glass melter, a radiant tube glassmelter, and a submerged combustion melter.

Glass melter designs, including the melter geometry and thespecifications of the energy input and control systems, must beadaptable to the composition of the first glass 206 and to aim at thesuccessful execution of the redox reactions while in the melter system,leading to the formation of the second glass 208. Examples of fuel firedglass melter types envisioned to be used in accordance with the presentinvention are one or a combination of a regenerative end or cross fuelfired melter, a recuperative end or side-fuel fired melter, and a hybridmelter (combination of fuel firing and electric boosting). Fuel firingis preferably carried out by oxy fuel burner systems.

Within an electric type melter the molten glass acts as a conductor ofelectricity and in the process it heats up. Under ideal conditions, asmuch as 95% of the electricity is converted directly into heat by jouleheating. The electrodes of the electric type resistance melter areplaced either inside or outside the glass pool formed by the first glassmelt 206. When the electrodes are placed inside the glass pool or glasstank, the electric type resistance melter operates in a direct heatingmode. In an indirect mode of operation, the electrodes are placedoutside the glass pool or the glass tank. In an all electric melter, themelter primary chamber geometry is determined based on the position ofthe electrodes in the melter, electrode current density, productionrate, load voltage, load power, and glass discharge types, such as abottom discharge, or a side charge. Alternatively, as disclosed earlierheat may be provided to the glass melter via other heating methods,singularly or in combination.

In hybrid melters, the energy input is provided by the dual action ofburning fuels and electrical boosting. The fuel burners are preferablyoxy-fuel burners and electrical boosting is provided by appropriate ACpower supplies.

Exemplary, the melting step 104 is carried out in a hybrid melter with asubmerged combustion burner that is inserted directly in the glass pool.Alternatively, the submerged combustion burner is placed in an auxiliarycompartment of the melter outside the primary melting area. A submergedcombustion burner is capable of firing gaseous and liquid fuels, aloneor in combination, such as firing with natural gas, hydrogen, and othercombustible gases and fuel oils. Air, oxygen, oxygen-enriched air isused as the fuel oxidant. The submerged combustion burner operates toprovide either an oxidizing or a reducing atmosphere. Submergedcombustion burners achieve localized temperatures in excess of 1600° C.

Referring now briefly to the illustration of FIG. 3, in FIG. 3 isillustrated schematically a glass melter system 300 envisioned to beused in accordance with one embodiment of the present invention. Glassmelter 300 according of the present invention comprises three zones,namely a melting zone 310, a processing zone 320, and a discharge zone330. In the melting zone 310, apart from phenomena that are related tothe melting of the materials introduced into the melter, the RAGcomponents 204 may be as well introduced, as mentioned above, eitherdirectly into the glass melt, or as additional RAG components 204 mixedwith the materials to be melted. The processing zone 320 is intended toallow at least the following processes to take place in the meltersystem 300: the introduction and incorporation of the RAG components 204into the first glass melt 206, holding and storing the first glass melt206, homogenizing the first glass melt 206, refining the first glassmelt 206, and reheating the first glass melt 206. The discharge zone 330comprises at least one or a combination of a trough, an outlet throat,an airlift system, glass re-heaters, plenum air heaters, and otherrelated auxiliary components.

In an all electric melter or a hybrid melter, additional electrodes areoptionally installed between the melting zone 310 and the processingzone 320, and between the processing zone 320 and the discharge zone 330to act as a barrier between the zones while maintaining the temperatureof the glass melt flowing from the melt zone 310 into the processingzone 320, and into the discharge zone 330. This prevents an undesirableglass melt return-flow between the zones of the melter system 300.

In accordance with a possible embodiment of the present invention, themain source of energy of the melting zone 310 is an oxy-fuel heatingsystem with the appropriate burners installed along the sides of themelting zone 310 structure. The energy input for melting is furtherincreased by an electric boosting system in the melting area. A boostingsystem in the melting area supplies additional energy directly to theglass bath and leads to a higher melting capacity.

In accordance with one embodiment of the present invention, theprocessing zone 320 is compartmentalized, for example with the help ofrefining banks placed at equal or varying glass depths to allowincorporating RAG components 204 into, and/or refine the first glassmelt 206. Movable gates/barriers are also installed between thecompartments to provide the ability to divert or bypass the molten glassto move upwards, downwards, or side ways towards the glass dischargezone 330 while maintaining a high temperature.

In accordance with an embodiment of the present invention in an allelectric melter system 300, the electrodes are installed into themelting zone 310 from the top. The electrodes are inserted through themelter plenum structure and enter the glass pool through the melt opensurface. This way they can be pulled out of the melter for inspectionand possible replacement. In such an arrangement, the formation of anelectrically conductive layer on the top of the melter, such as moltensalts must be either avoided, or disrupted. This is because theelectrodes' leads at the entry region into the melt pool will becontacted with the conductive layer and thus will experience a very highcurrent density, almost equivalent to being short out. If left exposedfor long enough time to the conductive layer, the electrode lead will beseverely damaged.

Should the formation of a conductive salt layer be likely, theelectrodes may enter the melter through side wall blocks of therefractories or from the bottom. If metals collect at the bottom of themelter, care needs to be taken to keep out the precipitated metals awayfrom the electrical path of the electrodes. In a situation when metalprecipitation results in formation of a molten metal layer at the bottomof either the melting zone 310, or the processing zone 320, a slopedbottom is provided to collect and discharge the molten metal layer in acontrolled manner out of the melter via a corresponding bottom dischargeprovided in each zone.

The electric melter system 300 uses various electrode materials, such asnon-metallic electrodes such as graphite, ceramic electrodes such asmolybdenum di-silicide, and metallic electrodes. Exemplary for the metaland metal alloy electrodes are electrodes made of molybdenum, molybdenumalloyed with zirconium oxide, molybdenum coated with molybdenumdi-silicide, copper, nickel-chromium super alloys such as Inconel® alloy690, and iron, among others. The metal electrodes may additionally bewater or air cooled to prolong the service life of the electrodes. Airor water cooling of the electrodes in the electric type resistancemelter alleviate the limitations in operating temperature and shift theoperating temperature to higher temperatures than otherwise would bepossible. In one embodiment of the present invention, indirect electricheating substitutes or complements the direct electrical heating, byusing for example molybdenum disilicide electrodes.

The batch 200 is charged preferably over the entire area of the meltpool in the melting zone 310 through one or a combination of doghouseson a side wall, and from the melter top. The batch 200, from a feedhopper, is spread over the molten glass pool for example by a vibratorychute. The batch floats on the top of the glass pool, and is optionallypushed or swept by a pusher to form a cold cap. The cold cap greatlyreduces radiation heat losses to the melter plenum space, and providesan efficient barrier against particulate emission to the melter off gassystem.

In accordance with the present invention, the melter system 300 ispreferably continuously fed, and continuously drained through one of anairlift system, and/or gravity, and/or a forehearth. The extent anddepth of the cold cap is adjusted by controlling the rate of feeding thebatch 200 to the melter, and the rate of discharging glass out of themelter. Exemplarily, a cold cap layer provides above 80% surfacecoverage over the melt pool having an average layer thickness, rangingfrom several centimeters to tens of centimeters. As a result, theoverall thermal efficiency of the melter is improved as indicated by anaverage power consumption of equal or preferably less than one Kwh perkg of the first glass 206 produced. The power consumption number variesdepending on the yield of the batch 200 to the first glass 206. As anexemplary case, a yield almost equal to one indicates that a low volumeof volatiles is lost from melting the batch 200 to the first glass melt206.

It is advantageous to provide a bottom drain situated at the bottom ofthe melter, in either one of zones 310, 320, and 330 to drain the glassor the potentially molten metals from the bottom of the melter. Thedrain nozzle is heated by electric heating means. The electric heatingheats the glass or metal in the drain-hole and maintains the temperaturenecessary for the required draining rate. Glass is drained from thebottom by the action of the gravity. The drain can be started or stoppedat any time by switching the electrical heating means on or off.

Air or other gases are blown into the melter through special bubblernozzles installed in either one of the melter bottom, side, and/orentering the glass melt from the top. This produces bubbles in the glassand as the bubbles rise to the surface of the glass melt, keeps theglass melt pool in the melter agitated. The bubbling gas is exhaustedinto the melter off-gas system. The upward movement of the bubblesproduces strong localized convection currents around their path, andthese currents move the glass upwards and cause an increase in the glassmelt temperature at the bottom of the glass pool, which otherwise wouldbe cooler than the top. The bursting bubbles on the glass surface alsocreate an effective barrier that prevents the unmelted batch from movingdownward prematurely. In most cases, bubbler tubes made from durablerefractory materials such as molybdenum disilicide, and are installed instrategically elected points in the melter for maximum effectiveness.

The melting time is defined as the residence time of a portion of thebatch 200 from a time that the batch 200 is fed to the melter till thetime that the first glass 206 is discharged in step 204. The residencetime of the first glass in the melter system in step 204 is estimated asthe capacity of the melter in kilograms, divided by the batch feed rateto the melter, in kilograms per hour. The residence time is measured inhours. The residence time of the batch 200 in the melter system 300until the discharge of the first glass melt 206 under continuous andnon-interrupted operation is less than 18 hours, and preferably under 12hours, and most preferably is equal to or under 5 hours.

In accordance of the present invention, irrespective of the type ofmelter used, the melting temperature of the batch materials 200 isbetween 1200 to 1600° C. The actual value of the temperature in thisrange is strongly correlated with the chemical composition of the batch200.

A plurality of non-equilibrium redox reactions take place while and/orafter the batch 200 is melted into the first glass 206 in step 204.

When RAG components are an integral part of the batch 200, or when theRAG components are added in the melter 300 or when both cases arepresent, then the batch 200 has to reside in the melter a time that islong enough to melt into a first glass melt 206. However, the residencetime in the melter should not exceed the time that is required tocomplete the redox reactions that will be initiated by the RAGcomponents 204. Hence, in order to achieve the desired non-equilibriumredox reactions, the reactions need to be terminated for example bymoving or discharging the first glass melt 206 from the melter. As such,the temperature of the glass melt is dropped and the glass solidifies,and the corresponding redox reactions are not able to proceed in thesolid glass to reach their equilibrium points.

Since the melting residence time is kept relatively short, a fasterdissolution of the batch materials 200 has to be ensured. To ensureefficient heat transfer and thus faster dissolution of the batchmaterials 200 into the glass pool in the melter, the melt is preferablyagitated, in accordance with one embodiment of the present invention.Melt stirring or agitation is achieved by at least one of an electricalmeans, such as electric current convection, a thermal means, such asforced thermal convection, mechanical means, such as stirring, andbubbling means. Bubbling gases via lances (bubblers, nozzles) into theglass pool is an efficient way to provide agitation in the melt pool.According to the present invention, oxidizing, reducing, and neutralgases and/or vapors and/or aerosols are as well used for bubbling theglass pool. Oxidizing, reducing, and neutral gases and/or vapors and/oraerosols are elected to be introduced into the glass pool depending onthe redox reactions to be initiated or enhanced or terminated in theglass melt. For example, to provide an oxidizing melt environment,oxygen or a mixture of air and oxygen is used. To provide for a reducingenvironment, for example forming gas (mixtures of hydrogen andnitrogen), hydrogen sulfide, a variety of gaseous hydrocarbons, andammonia is used. To provide for a neutral environment, air, and/ornitrogen, or inert gases are used.

The flow rate of the bubbling gas or of the other media provided isadjusted as appropriate, adjustment that can vary from several litersper hour to tens of liters per minute. The numbers of lances/bubblers,their locations, together with the airflow patterns from the lances intothe melt pool are adjustable in order to provide for the desiredresidence time and the desired redox state of the first glass melt 206before being discharged from the melter. In accordance with oneembodiment of the present invention, the bubblers are located at or nearthe bottom portion of the melting chamber beneath the glass pool, forproviding the gas bubbles directly into the glass melt. Bubbling orpurging gas and/or aerosols may be provided as well in other parts ofthe melter, outside the main melting chamber, as will be disclosedlater.

Glass mixing efficiency should be balanced against the melt pool contactrefractory erosion rate. Accordingly, to achieve non-equilibrium redoxstate in the first glass melt 206, it is within the scope of presentinvention to maximize the melting rate while keeping the eroding rate ofthe contact refractories reasonably low.

In one aspect of the invention, the gases and/or aerosols used forproviding agitation in the glass melt, for example by bubbling, can alsotake part in providing the non-equilibrium redox reactions in the firstglass melt 206, and thus as such are considered to be “part of the RAGcomponents” 204. The gaseous and/or aerosols RAG components thus havethe dual function of providing agitation in the glass melt/pool and atthe same initiating and/or assisting, and/or terminating thenon-equilibrium redox reactions of the first glass melt 206. In oneembodiment of the present invention, the gaseous and/or aerosolic RAGcomponents 204 are introduced in the processing and discharge zone 330of the melter system 300. Exemplarily, they may also be introduced inthe processing zone 320, that exemplarily comprises one or a combinationof a holding and storing section, a homogenizing section, a refiningsection, a reheating section, sections that all pertain to the firstglass processing zone 320. Exemplarily, the gaseous and/or aerosolic RAGcomponents 204 are introduced in the discharge zone 330 that comprisesone or combination of trough and/or outlet throat section, and theairlift section, sections that pertain to the first glass discharge zone330.

The introduction of the RAG components 204 in the melter system 300results in the initiation, continuation and enhancement, or thetermination of the non-equilibrium redox reaction taking place in themelter system 300. In accordance with the present invention, concurrentredox reactions may take place in the melter system 300, and multipleRAG components 204 may be introduced simultaneously or in stages toprovide for either one or a combination of initiation,enhancement/continuation, and termination of the corresponding redoxreactions.

In accordance with one aspect of the present invention, the melting step104 comprises the further introduction in the first glass melt ofspecific RAG components 204, that are introduced by at least one ofbubbling, injection, or by any other introduction method into the firstglass melt 206 in order to incorporate certain desirable chemical and/orredox properties into the first glass melt 206. Exemplarily, the furtherRAG components are introduced by bubbling oxygen into the first glassmelt 206 in order to shift the glass redox to be more oxidizing.Exemplarily, hydrogen is also introduced as RAG component 204 to reducethe oxidation state of the first glass melt 206. Because of the directincorporation of the further RAG components 204 into the first glassmelt 206 fast redox changes are induced in the first glass melt 206.These redox changes, that take place fast in the first glass melt 206,also affect the oxidation state of the multivalent metal ions present inthe first glass melt 206 as a part of the RAG components 204. Single andmultivalent metals can be added as a part of the RAG components 204directly to the first glass melt 206 for scavenging oxygen from theglass and in the process forming the corresponding metal oxides.

An advantage of introducing gaseous and/or aerosolic RAG components 204in the discharge zone 330 of the melter system 300 is that theintroduced RAG has the dual function of lifting the molten glass and atthe same time providing for non-equilibrium redox reactions in themelter system 300. In an exemplary case, the introduced RAG components204 terminate the redox reaction(s) taking place in the first glass melt206 present in the discharge zone 330 of the melter system 300, or inanother case, initiate a redox reaction that will be continued in thesecond glass 208 when said second glass 208 is melted in a firingfurnace. Another advantage is that the non-equilibrium redox reactionsare isolated to the glass present in the discharge zone 330, and thusonly affect the glass being discharged and not the entire glass poolresiding inside the processing and melting zones 310, and 320.

Therefore, advantageously the first glass melt 206 present in the mainglass pool residing in the melting zone 310 is enabled to selectivelyhave a redox state that is the least damaging or corrosive to the melterelectrodes and contact refractories, but is different from the targetedredox. The redox of the first glass melt 206 is subsequently adjustedand tuned to the desired state downstream from the main glass pool, forexample in the processing zone 320, and/or in the discharge zone 330, orin any other auxiliary chambers present in the melter 300 before thefirst glass melt 206 is finally discharged from the melter system 300.

As mentioned before, instead of or in combination with the glass meltingby Joule heating, other forms of glass melting are also within the scopeof the present invention including melting using a plasma torch, aninductively coupled source, a fossil fuel source, a submerged burner,and a combination thereof.

For example, in the case of employing iron as the multivalent metal inthe RAG components 204, by creating a reducing condition in the meltersystem 300, a portion of the ferric ions is converted to ferrous ions.Also, in another example, incorporating hydrogen sulfide as a part ofthe gaseous RAG components in the first glass melt 206 has the dualeffect of reducing the glass and forming a metal sulfide. As mentionedabove, the presence of sulphur in the form of sulfate and sulfide in thesecond glass melts 208 leads to the formation of sulfur dioxide in theglass, with the desirable effect of creating the glass microspheres.

In accordance with another embodiment of the present invention, the RAGcomponents 204 are introduced in the first glass melt 206 in the meltersystem 300 as liquids in the form of liquid aerosols.

The liquids, in the form of either one of liquid droplets (mist),stream, aerosol or a combination thereof, are injected into the firstglass melt 206 while in the melter system 300. For example, a liquid-gasmixture is injected into the first glass melt 206 while in the meltersystem 300 or while the first glass melt 206 is discharged from themelter 300. The liquid may be water based, or liquid organic based.Exemplarily, water dissolves in the first glass melt 206 in relativelylow quantities (e.g. about 0.1 to 0.2 wt %), but it is a very powerfulfluxing agent in the glass, and lowers the viscosity and the meltingtemperature of the resulting glass. In addition, water is an effectiveblowing agent, useful in expanding the second glass melt 208 containedin the silicate glass fragments 210, into hollow glass microspheres 212.

In accordance with yet other aspects of the present invention, the RAGcomponents 204 added to the first glass melt 206 are presented as solidsand liquids in the form of a fine powders, spray or fine droplets, solidaerosol, liquid aerosol, or a combination thereof, and added as such toeither the batch 200 and/or the first glass melt 206.

Solids, exemplarily in the form of either fine powders or solid aerosol,are injected into the first glass melt 206 at various locations in themelter system 300. For example, carbon in form of coke or fine graphitepowder in a gas carrier stream or liquid carrier stream is injected intothe first glass melt 206 to induce reduction of the chemical species ofthe first glass 206 via corresponding redox reactions. In the process,the carbon oxidizes to carbon dioxide and/or carbon monoxide, leavingthe melter system 300 through the off-gas system. Metal powders such asmagnesium, copper, iron, etc. also when added directly to the firstglass melt 206 as a part of the RAG components tend to oxidize in themolten glass without producing any appreciable gaseous reactionproducts.

Liquids, exemplarily in the form of liquid aerosol, slurries, and spray,are also injected into the first glass melt 206 at various locations inthe melter system 300. For example, solutions, slurries, organicsliquids, hydrocarbons, fuels and alike are injected with or without agas carrier into the first glass melt 206 to provide corresponding redoxreactions.

The first glass melt 206 formed from a batch comprising the SGP rawmaterials 202 and the RAG components 204 has a melting temperature above1000° C., and preferably between 1200° C. and 1500° C.

Exemplarily, gaseous RAG components 204 are air, oxygen, nitrogen,hydrogen, steam, hydrocarbons, gaseous organics, CO₂, CO, H₂O (vapor),SO₂, SO₃, H₂S, NH₃, and a combination thereof. Exemplarily, theinjectable liquid RAG components 204 are one or a combination of liquidwater, peroxide, sulfuric acid, liquid fuels, organic liquids, slurries,and solutions of various chemical species. Exemplarily, the injectablesolid RAG components 204 are solid carbonaceous materials such asanthracite powders, graphite powders, metallic materials such as irondust, and various chemical species such as sulfur, nitrides, borides,carbides, etc.

As noted previously, if the SGP raw materials 202 already include redoxactive components intrinsically, then the redox active componentscomprised by the SGP raw materials 202 are counted as a part of the RAGcomponent 204. Solid RAG components 204 that may be intrinsicallypresent in the SGP raw materials 202 include iron bearing minerals andoxides, multivalent metal oxides, and sulfur bearing compounds andminerals such as gypsum, salt cake, carbonaceous materials, such ascarbon, or a carbon containing material(s).

The first glass 206 preferably has a total alkaline metal oxides contentof less than 12 wt %, more preferably, less than 10 wt %, and mostpreferably less than 6 wt %. The preferred concentration of sodium oxidein the first glass 206 is less than 10 wt %, and more preferably lessthan 8 wt %, and most preferably less than 4 wt %. All the wt % (weightpercentage) numbers are calculated based on the mass of the first glass206.

Discharging the first glass melt 206 from the melter may be carried outby using a gaseous RAG component 204, or a gaseous stream/carrier thatincludes a RAG component 204 to lift the glass melt and discharge it outof the melter. According to this embodiment of the invention, the gasstream has the dual function of lifting the glass out of the melter 300and providing the RAG components 204 needed for triggering thenon-equilibrium reactions.

By discharging the melted batch 200 or the first glass melt 206, and asthe glass cools to room temperature, the redox reactions taking place inthe glass melt are conveniently terminated or stopped from progressing.There are different ways to discharge the first glass melt 206 from themelter 300. Exemplarily, the first glass melt 206 is discharged by anairlift system, out of the melter system 300 from the side or from thetop of the melter 300. Another option is to gravity discharge the glassfrom the bottom. It is also envisioned to discharge the glass byoverflowing into a trough as the glass inventory inside the primary meltpool (e.g. melting zone 310) reaches a threshold. In another melterconfiguration, the melter may be tilted in order to discharge the glass.

Any or a combination of discharge methods may be employed to adopt andcouple the discharge operation to the steps of processing the glass instep 106, such as simultaneous forming operation and cooling the firstglass melt 206. Exemplarily the discharge methods are discharging theglass between air-cooled or water-cooled counter rotating a pair ofmetal rollers to simultaneously forming glass ribbons, and cooling thefirst glass melt 206.

In accordance with the present invention, the method 100 also comprisesa step of processing 106 of the first glass melt 206, that was createdat least by the step of melting the batch 200 at step 104. At step 106,the first glass melt 206 is processed into a second glass 208.

In accordance with various embodiments of the present invention, theprocessing step 106 comprises at least one or a combination of thefollowing steps: shaping/forming the discharged first glass melt 206 andcooling the first glass melt 206.

According to the present invention, the glass that is discharged fromthe melter 300 and cooled to room temperature is identified as thesecond glass 208.

Within step 106, the first glass melt 206 is cooled forming solid glassof various forms and shapes. The solid forms comprise a plurality offlakes, fragments, ribbons, fibers, sheets, rods, pellets, gems,spheres, or a combination thereof. It should be noted that any othershapes of the second glass 208 are within the scope and spirit of thepresent invention. In one embodiment of the invention, a heat and steamrecovery system is also employed to recover either the heat and/or thesteam liberated by the first glass melt 206 during the cooling step 106.The recovered heat is utilized for various purposes, includingpreheating the batch 200, or for heating the primarily and the secondaryair utilized in a firing furnace in step 110.

In one embodiment of the present invention, air cooled or water cooledsteel rollers are used to cool and flatten the discharging molten firstglass 206 into a thin ribbon that can be easily broken up into smallfragments.

In accordance with another embodiment of the invention, the dischargingmolten first glass 206 is water quenched by directing and dropping thedischarging molten first glass 206 directly into a water bath. Due tothermal shock, in contact with water, the suddenly cooled molten glassshatters into small fragments. This is an effective way of cooling andfragmenting the molten first glass 206, followed by a drying step beforefurther size reducing the resulting fragments of second glass 208.

In accordance with one embodiment of the present invention, upon coolingin step 106, the solid second glass 208 is pulverized in step 108 toprovide a plurality of glass fragments (SGF) 210 having a predeterminedaverage particle size, and particle size distribution. In accordancewith one embodiment of the present invention, step 108 includes one ormore size reduction processes, such as a coarse pulverization stepfollowed by a finer size reduction step, and a screening step.

According to the present invention one or a combination of hammer mills,jaw crushers, and rotary crushers are used for coarse grinding of thesecond glass 208. One of centrifugal mills, disc mills, ball mills, jetmills, impact mills, high-speed rotary mills, and similar equipment mayalso be used for finer size reduction of the fragments obtained from thecoarse grinding of the second glass 208. Without being bound to aspecific size reduction method, fluid bed jet milling is a preferredmethod of fine grinding and size reduction and classification of theglass particles suitable for use as the plurality of glass fragments SGF210. The fluid bed jet mill incorporates dense phase micronization usingopposing jets in combination with centrifugal air classification, allwithin a common housing. This combination allows for comminution/sizereduction by particle on particle impact for breakage and a high degreeof particle dispersion for improved separation resulting in a narrowerparticle size distribution, zero to very low contamination, and a loweroverall energy consumption compared to other commercially availabletechniques. This size reduction method ideally provides a top particlesize of about 150 microns, with a tunable narrow size distribution at adesired range (for example between 50-120 microns), and having a tailend of the particle size distribution at less than 5 wt % below 5microns. Should larger top size SGF fragments be desired, e.g. above 150microns, a disc mill equipped with an air classification unit is used.

The silicate glass fragments 210 are as well screened in step 108. Theundersized fraction of the silicate glass fragments 210 is optionallyrecycled back to the batch 200 in step 102 to be blended in, or to bedirectly fed to the melter 300. On the other hand, the oversized portionof the silicate glass fragments 210 is optionally recycled back to thefine grinding step to be size reduced. The preferred average particlesize of the silicate glass fragments 210 is determined by end use of theplurality of the glass microspheres 212 manufactured in accordance withthe present invention. For example, if the glass spheres 212 are to beused in the oil and gas well drilling cement (i.e. drilling mud), oiland gas well casing, and oil and gas hydraulic fracturing applications,the average particle size of the silicate glass fragments 210 is in arange of 1-1000 microns, preferably in a range of 5-600 microns. Atypical ratio of the particle size of the hollow glass microspheres 212(spherical diameter) to the average particle size of the silicate glassfragments 210 (e.g. equivalent spherical diameter) is from 1.01 to 3.0and preferably from 1.035 to 2.7. A ratio of greater than one means theglass microspheres 212 are expanded compared to the silicate glassfragments 210. Exemplary, at a ratio of 1.5, a silicate glass fragment210 at an average particle size of about 100 microns forms a hollowglass microsphere 212 of an approximate average particle size of 150microns. The particle density (apparent density) of such glassmicrosphere is estimated from the expression:ρ_(h)=ρ_(f)(d _(f) /d _(h))³where ρ_(h), and ρ_(f) are the apparent particle density of the glasssphere 212, and of the silicate glass fragment respectively, and d_(f),and d_(h) are the mean diameter of the silicate glass fragment 210, andof the glass sphere 212, respectively. The apparent and true densitiesof the glass fragment 210 are essentially equal, with the assumptionthat there are no substantial internal porosities in the glass fragment210. Assuming an apparent particle density of 2.4 g/cc for the silicateglass fragments, the estimated particle density of the glass microsphere212, having a particle size of about 150 microns is about 0.7-0.75 g/ccat a ratio of 1.5. Exemplarily, at a ratio of 2.4, the resulting hollowglass microsphere 212 would have a particle size of about 240 microns,and an approximate particle density of about 0.17-0.18 g/cc.

The above examples assume that the apparent particle density of theplurality of glass fragments 210 is about 2.4 g/cc (e.g. equal to theparticle true density). It must be understood that the glass fragments210 may include micro-bubbles throughout their volume, and as a resulthave a lower apparent particle density than 2.4 g/cc. Nevertheless,according to the present invention the glass fragments 210 areconsidered substantially solid.

The method 100 of manufacturing a plurality of glass microspheresfurther comprises the step 110 of thermally processing the plurality ofsilicate glass fragments 210 to convert said plurality of silicate glassfragments 210 into a plurality of glass microspheres 212. Saidconversion occurs due to the provision of at least one of a plurality ofredox reactions and plurality of events in at least one of the firstglass melt 206, and a melt of the second glass 208, the plurality ofredox reactions and the plurality of events being induced by a pluralityof redox active group (RAG) components 204.

In step 110, the plurality of glass fragments 210 is heated in afurnace, preferably in a suspended state, to a temperature where theviscosity of the glass is less than 10⁵ poise, preferably less than 10⁴poise, and most preferably less than 10³ poise, temperature at which thesilicate glass fragments 210 assume a round shape while residing in thesuspended state inside the furnace. A temperature at which the aboveenumerated conditions are fulfilled is denominated the “firingtemperature” and the time necessary for the above enumerated conditionsto occur is denominated “residence time”. The redox reaction(s) inducedor associated with the RAG components 204, this time present in thesecond glass melt 208, (including the reaction products of the RAGcomponents formed previously by the non-equilibrium redox reactions inthe first glass melt 206) generate at least one gaseous productexpanding the softened plurality of glass fragments 210 into a pluralityof hollow glass microspheres 212 while in the furnace.

The plurality of glass fragments 210 comprise the second glass 208.

The redox reactions occurring in the second glass melt 208 are affectedby either one of the oxygen concentration and the fugacity in thefurnace hot zone within the atmosphere surrounding the softenedplurality of silicate glass fragments 210. The redox reactions that aretriggered by the RAG components 204 within the softened glass fragments210 are somewhat sensitive to the oxygen fugacity within the heated zoneof the furnace.

According to the present invention, the process of gas generation withinthe heated glass fragments 210 coincides with the formation of fluxesthat tend to lower the melting temperature of the second glass 208. Theredox reactions associated with the RAG components 204 provide gaseousproducts that expand the molten plurality of silicate glass fragments210 into the hollow glass microspheres 212. Also, the redox reactionsassociated with the RAG components 204 provide fluxing oxides that lowerthe melting temperature of the second glass 208 as compared to themelting temperature of the first glass 206. In order to facilitate theoccurrence of the redox reactions in the second glass melt 208 inaccordance with one embodiment of the present invention, an appropriateatmosphere for the operation of the firing furnace is established, whilethe glass fragments 210 are being heated, melted, and expanded into theglass microspheres 212. It has been found that firing a gas burner nearits stoichiometric oxygen-to-gas ratio provides said appropriateatmosphere and is an appropriate condition in the furnace that providesa relatively neutral atmosphere surrounding the silicate glass fragments210 while in the hot zone of the furnace.

In accordance with an embodiment of the method of the present invention,heating and converting the silicate glass fragments 210 to a pluralityof glass microspheres 212 occurs by heating them in a combustion zoneinside a fossil fuel-fired furnace, in particular a gas-fired furnace.In such a configuration, the combusting process provides the necessaryheat for converting the silicate glass fragments 210 to the hollow glassmicrospheres 212. In addition, the air-gas mixture entering the furnace,and the combustion flu gases exiting the furnace, provide gas phasetransfer for the silicate glass fragments 210, and for the glassmicrospheres 212 in and out of the combustion zone of the furnace,respectively.

In accordance with the present invention, other heating sources may beemployed instead of or in combination with a fossil fuel fired furnace.These heating sources include but are not limited to electric heating,plasma heating, RF heating (microwave), and IR (infrared) heating. Thefossil fuels according to the present invention may comprise a varietyof gaseous fuels, such as natural gas, propane, liquid fuels, such asheavy liquid fuel oils, distillate fuels, such as kerosene, solid fuels,such as coal and other organic solids, and a combination thereof. Thepreferred fuel is natural gas, which is readily accessible in the mostgeographical areas, burns clean, suits the widely available range ofburner configurations, and is suitable for co-feeding of solidparticles.

In accordance with one aspect of the invention, the gas-fired furnaceemployed is preferably of the vertical type, in which the combustion ofair and gas creates a turbulent combustion zone. As the temperature ofthe silicate glass fragment 210 reaches the working temperature of thesecond glass 208 (e.g. working temperature corresponds to a glassviscosity of about 10,000 poise) the fragments assume a viscoelasticstate, at which they are capable of entrapping gaseous products beingcreated via the redox reactions or by other means, and are capable toexpand. The expansion action forces the silica glass fragments 210 toblow from inside out to form the plurality of hollow glass microspheres212. Thereinafter, the plurality of hollow microspheres 212 is conveyedout of the furnace by the combustion flu gases. Preferably, apredetermined volume of cooling air is introduced downstream from thecombustion zone to cool the glass microspheres 212, while the glassmicrospheres 212 are being conveyed out of the furnace.

It is important that the softened glass fragments 210 and the newlyformed glass microspheres 212 do not impinge on the interior hardsurfaces of the furnace. Otherwise, they will adhere to the interiorhard surfaces forming a tacky layer that leads to a sticky substratethat encourages further glass build-up during the operation of thefurnace. In addition, there should be enough separation distance betweenthe glass particles in the furnace in order to avoidparticle-to-particle interaction/impingement to the extent possible;otherwise, the agglomeration of particles becomes a problem. The glasslayer buildup on walls or the interior surfaces of the furnace inaccordance with one embodiment of the present invention is stopped byproviding an air curtain near the wall to keep the particles away fromthe wall, or by other known techniques. Particle to particle impingementfrequency is minimized by reducing the amount of particle loading of thesilicate glass fragments 210 in the gas phase, entering and exiting thecombustion zone of the furnace.

The plurality of the glass microspheres 212 is immediately cooled afterexiting the combustion zone of the furnace in step 112. Cooling airand/or dilution air is introduced inside the furnace downstream from thecombustion zone, which cools the glass microspheres rapidly to below thesoftening temperature of the glass. Additionally, cooling air and/ordilution air may also be introduced in the ductwork after the furnacethat is leading to the off-gas treatment system. In the off-gastreatment system, the plurality of hollow glass microspheres 210 isseparated from the carrier gases (e.g. flu gas plus dilution air) incyclones and/or various filtering systems. The plurality of hollow glassmicrospheres 210 is then cooled to room temperature by appropriatemeans, collectively in step 112. Mechanical and/or pneumatic means areused for further transport of the glass microspheres 212 to storageareas or to loading stations within or outside the manufacturingfacilities. Sampling ports are provided at various locations downstreamfrom the furnace to collect samples of the glass microspheres 212.Samples are analyzed at least for the bulk and particle densities, andpercentage of sinkers and floaters. Based on the results revealed by thesample analysis, appropriate corrective actions may be carried out toadjust the desired properties of the spheres, including but not limitedto adjusting the firing temperature, the residence time, and the ambientatmosphere in the furnace.

The need and the availability of the RAG components 204 that are addedto the first glass melt 206 is ascertained as well by measuring thedensity of the produced glass microspheres 212. Should the density ofthe glass microspheres 212 produced be lower, then more gas is necessaryto produce glass microspheres 212 with a lower density. Therefore, muchmore RAG components are added to the first glass melt as needed. This isafter the firing temperature and the residence time in the furnace areoptimized and fixed. As such, RAG components 204 with larger capabilityof gas generation should be included in the second glass melt 208. Thenecessary RAG components may be added to the first glass melt 206 in themelter system 300 as one option, and to the batch 200, as anotheroption. One advantage of adjusting the RAG components in the glassmelter 300, and specifically, in the processing and/or discharge zonesof the melter system 300, as opposed to making a corrective action inthe batch 200 is that it takes a significantly shorter turn around timeto accomplish the corrective action on the density of the produced glassmicrospheres 212. Another advantage is that a relatively low volume ofpotential glass reject, which is off the desired specification, needs tobe dealt with. The capability of adjusting the RAG components 204 in themelter system 300 also makes it possible to manufacture glassmicrospheres 212 with varying densities on a non-interruptive basis.Hence, the present invention provides a method of adjusting or varyingdensities of the glass microspheres in a very quick and efficient wayvia adjustments of the RAG components 204 in the melter system 300.Exemplarily, the particle density of the glass microspheres 212 is asensed parameter (for example measured by a pycnometer) that is fed backto a control mechanism thatadjusts the RAG components (e.g. types andamounts) in a closed or open loop control fashion. The control tactic ormethodology is built in an existing empirical database that includes thevariation of the sensed parameter (e.g. density) as a function of typesand amounts of the RAG components 204. It would be apparent to a personskilled in the art how such a control mechanism may be implemented, forexample manually and/or automatically.

The residence time in the furnace is determined as the average time thatthe glass fragments spend in the heated zone of the furnace. Therefore,the residence time is calculated as the length of the heated zone of thefurnace divided by the linear velocity of the silicate glass fragments210 travelling through the heated zone. The residence time of the glassfragments in the furnace is within a fraction of a second to less than10 seconds, and preferably from 0.2 seconds to 4 seconds. However, aresidence time outside the range specified above is as well within thescope of the present invention. In general, the residence time is afunction of the peak firing temperature and reflective radiative heatinginside the furnace, which is controlled by the geometry and operatingmode of a firing furnace.

Exemplarily, the furnace may be a vertical furnace that is fed with thesilicate glass fragments 208 in an upward, or a downward fashion. It isalso within the scope of the present invention to utilize a firingfurnace that is not vertically oriented, such as a horizontally orientedfurnace, and an inclined oriented furnace. The orientation is defined asthe direction parallel to the longest axis of the furnace. An inclinedoriented furnace has a non-zero angle between the furnace orientationand the horizontal direction.

In accordance with one aspect of the present invention, the silicateglass fragments 210 resulting from grinding the second glass 208 aresubstantially free of large gas bubbles, but may contain advantageouslymicro-sized gas bubbles and/or nucleated micro-bubbles.

Nucleated micron and sub-micron size bubbles (collectively calledmicro-bubbles) formed within the first glass melt 206 due to theoccurrence of non-equilibrium redox reactions comprising any one or amixture of gaseous SO₂, SO₃, O₂, CO₂, H₂, CO, N₂, NO_(x), H₂O, etc., andcarried over to the second glass 208 are tolerable in accordance withthe present invention. The nucleated micro-bubbles in the second glass208 are carried through the remainder of the glass pulverizingoperations, and eventually are retained within the resulting silicateglass fragments 210. The total volume of the micro-bubbles within asilicate glass fragment 210, compared to the total volume of thesilicate glass fragment 210 is relatively small, i.e. several percentagepoints or less. As the silicate glass fragments 210 are reheated in thefurnace to the firing temperature, the nucleated micro-bubbles expandand grow in size, an event that is referred to according to the presentinvention as “thermal reboil”. The growth rate of the nucleated bubblesin the second glass melt 208 becomes significant above 1100° C., andespecially between 1200-1500° C. The thermal reboil alone and/or incombination with the other gas generation means, such as physicalreboil, redox reactions, and sublimation, leads to the formation of thehollow glass spheres 212. These aspects of the present invention will beexplained in detail in the remainder of the present document.

In accordance with another aspect of the present invention, physicalreboil, which is also the result of incorporating the RAG components 204either in the batch 200, and/or to the first glass melt 206 in themelter system 300, contributes as well to the expansion of the silicateglass fragments 210 to hollow glass microspheres 212. The physicalreboil process occurs due to changes in the solubility of the chemicalspecies in the glass melt as a function of temperature under atmosphericconditions. The onset and the rate of the physical reboil gas evolutionis affected by the composition of the second glass melt 208, as well asby changes in the furnace ambient conditions, that affect thesolubilities of dissolved gases in the second glass melt 208. Forexample, in one embodiment of the present invention, the presence ofsulfur as sulfate in the second glass 208 leads to “sulfur reboil” uponheating the silicate glass fragments 210 in the furnace. For example,the solubility of dissolved SO₃ in the second glass melt 208 decreasesby about 3 orders of magnitude upon heating from 1100° C. to 1400° C.Hence, in the event that the concentration of SO₃ in the second glass issuch that it exceeds the solubility limit above 1100° C., a physicalreboil occurs which is associated with the release of SO₃ from theinterior of the silica glass fragments 208, resulting in expansion ofthe silica glass fragments 210, and thus in the formation of the hollowglass microspheres 212. The onset of the physical reboil is alsodependent on the equilibrium partial pressure of oxygen in the heatingzone of the furnace. The phenomena of the thermal reboil, sublimation,and the physical reboil are referred to further generally as a pluralityof events that take place in the melt of the second glass 208.

Aside from the thermal and physical reboils, the present inventionrelies primarily on the RAG components 204 to provide redox reactionscapable of generating gaseous reaction products to expand the silicateglass fragments 210 into the plurality of hollow glass microspheres 212,as it will be disclosed later in more detail.

The chemical reactions occurring in the second glass melt 208 inaccordance with the present invention comprise one or more of reactionsinvolving decomposition, oxidation, dissociation, reduction, andrecombination of chemical species associated with the RAG components204. Other forms of gas generation in a melt of the second glass 208 dueto physical events or processes such as nucleation, saturation,evaporation, and sublimation are also within the scope of the presentinvention, and are considered under the category of the plurality ofevents. Irrespective of how the gas is generated, the gaseous productsas they are being generated are either trapped, or entrapped, orentrained, or a combination thereof in the second glass melt 208 fromwhich the silicate glass fragments 210 are formed, and aid in formingthe plurality of hollow glass microspheres 212.

Preferred RAG components 204 in the batch 200 comprise sulfur (in theform of one or more of sulfates, sulfites, and sulfides), multivalentmetals, and transition metals in the form of compounds and chemicalspecies, and various carbonaceous materials including carbon itself. Asmentioned earlier, RAG components 204, in the form of gaseous, liquids,aerosols (solids and/or liquids) may be mixed, or injected, or purged,or bubbled, or a combination thereof, into the first glass melt 206.Common gaseous reaction products generated during RAG components redoxreactions (also referred to as RAG reactions) include SO₃, SO₂, H₂S,CO₂/CO, H₂O, O₂, NH₃, and NO_(x). Other gaseous species that might bepresent, such as entrapped air, and nitrogen are not considered a directgaseous reaction product. All the gaseous reaction products can be alsoused as gaseous RAG components to be purged or bubbled inside the firstglass melt 206 in addition to those listed before.

CO₂ and/or CO gas is released during the decomposition of carbonates,and/or due to oxidation of carbonaceous materials of the RAG components204. The carbonaceous materials of the RAG components 204 include bondedcarbon (in organic substances), unburned carbon (UBC) that is found inthermally processed industrial byproducts, graphite, carbide, coke,anthracite, carbocite, loose carbon powders, etc.

Sulfur containing gaseous reaction products are present whensulfates/sulfites/sulfides are included as a part of SGP raw materials202 and/or the RAG components 204. According to the present invention,all the sulfate/sulfite/sulfide ions, multivalent and transition metalions, and carbonaceous materials either in elemental or compound forms,other than carbonates in the resulting first glass melt, are consideredto be the constituents of the RAG components 204, regardless of havingbeen introduced intrinsically with the SGP raw materials 202, and/orwith the RAG components 204.

With respect to the sulfur portion of the RAG components 204, it is ofnote that sulfur solubility is sensitive to the oxidation state of thefirst glass melt 206. Under reducing conditions, sulfur dissolves assulfide ions, and as sulfate, while under oxidizing conditions. Thereduction of the oxygen partial pressure inside or outside the firstglass melt 206 shifts the equilibrium between sulfide and sulfatetowards sulfide, with a reduction in overall sulfur solubility,resulting in degassing the first glass melt 204 by releasing SO₂. Hence,the sulfide solubility is generally lower than the sulfate solubility inthe first glass melt 206. Changes in the chemistry of the first glassmelt 206 also alter the overall sulfur solubility (sulfates and sulfidesare referred to in general way as sulfur). In addition, the overallsulfur solubility depends on the first glass melt 206 temperature, sincethe sulfate solubility decreases with increasing the temperature, whilethe solubility of sulfide increases with increasing the temperature.Therefore, changes of temperature of the first glass melt 206 affect theconcentration of sulfur, in the forms of sulfate and sulfide, inopposite directions.

For example, to yield sulfides from sulfate in the first glass melt 206,(since the source of sulfur in the RAG component 204 is primarilysulfate), a reducing RAG component, such as carbon, is included in thebatch 200, and/or directly introduced into the first glass melt 206while inside the melter system 300. Since redox reactions are time andtemperature dependent, according to the embodiments of the presentinvention, a desired balance between the concentrations of sulfide andsulfate in the first glass melt 206 is achieved by adjusting theresidence time of the first glass melt 206 in the melter system 300.Said adjustment may be performed to adjusting the redox state of thefirst glass melt 206, that is controlled by the introduction ofadditional RAG components 204 directly to the first glass melt 206, andthe ambient conditions of the melter system 300.

In accordance with one aspect of the present invention, the plurality ofredox reactions comprise the reaction of sulfates with sulfides in thesecond glass melt 208.

The solubility of sulfur decreases with decreasing the alkali content ofthe first glass melt 206. The amount of sulfate ions (as SO₄) in thefirst glass melt 206, according to the present invention, is typicallyless than 5 wt % based on a combined mass of batch 200 that includesboth the SGP raw materials 202 and the RAG components 204. Thesolubility of sulfate as SO₄ in a typical first glass melt 206 accordingto the present invention is from about 0.2 to about 2.0 wt % based onthe mass of the first glass 206. Alkali sulfates, when present in thebatch 200, melt at a temperature of around 900° C., and remain in thefirst glass melt 206 as sulfate under an oxidizing condition untilappreciable decomposition starts to occur, at or above 1100° C. In acontinuous melting operation, the temperature rise occurs in the coldcap region, whereby the temperature of the fresh batch 200 on the top isconsiderably cooler than the batch temperature that is near the moltenglass underneath.

In the presence of reducing components in the RAG components 204, suchas the presence of unburned carbon, the decomposition of sulfates occursat a lower temperature, e.g. around 800° C.

Should an oxygen sink, internal or external to the first glass melt 206,or an oxygen getter, enter the first glass melt 206 as a part of thegaseous RAG components 204, the oxygen from the sulfate ion is consumedand/or scavenged in the first glass melt 206, and SO₂ gas is released.The results may be interpreted in terms of sulfate solubility andnon-equilibrium effects. For example, when a multivalent metal ion, suchas iron, is present as a part of the RAG components 204, both reducedand oxidized forms of sulfur (e.g. sulfate and sulfide), and iron (e.g.ferrous and ferric) may coexist in the first glass melt 206, andsubsequently in the second glass melt 208 that forms the silicate glassfragments 210, as a result of the non-equilibrium redox reactions takingplace in the first glass melt 206.

According to an embodiment of the present invention, a composite redoxvalue, calculated based on a concentration of the at least one electrondonor component and on a concentration of the at least one electronacceptor component in said first glass 206, is used to determine theamounts and types of the RAG components that are to be incorporated intothe first glass 206. In addition, when the entire quantity of RAGcomponents 204 is not incorporated from the beginning into batch 200,the composite redox value takes into account any RAG components 204 inany forms that are to be incorporated into the first glass melt 206within the melter system 300, in addition to taking into account theamounts added in the batch 200.

Exemplarily, when the RAG components 204 are incorporated directly intothe first glass melt 206, normally the rate of their addition isreported as a mass flow rate. One way to convert the mass flow rate toconcentration is as follows: Since the mass of glass produced per unittime is generally known, then the wt % of a particular RAG component ona mass basis of the first glass melt 206 is calculated as:(M_(RAG)*100)/(M_(Glass)+M_(RAG))where, M_(RAG) is the mass flow rate of the particular RAG component inkg/hr, and M_(Glass) is the mass of glass produced in kg/hr, prior toincorporation of the particular RAG component. Different units for massflow rate may be used, however, the unit used has to be the same unit asthe one used for reporting the mass of the glass produced per unit time.

The composite redox value is calculated based on concentrations of theRAG components 204 in the first glass melt 206. As mentioned earlier,the RAG components 204 overall are either electron donors or acceptors.To calculate the composite redox number, factors are assigned to thecorresponding concentrations of the RAG components 204 in the firstglass 206, in wt %. The factors are: for carbon as elemental carbon(−7.0), for sulfate as SO₄ (+0.5), nitrates as NO₃ (+0.2), and sulfidesas S (−0.6). Should other components be present in the RAG 204 a skilledperson would know how to assign the applicable coefficients to saidcomponents based on tables available in the art. In the above example, apositive factor indicates an oxidizing chemical species, and a negativefactor indicates a reducing chemical species. For example, in asituation whereby the first glass melt 206 comprises approximately 2 wt% sulfate as SO₄, and 0.4 wt % carbon, as C, the composite redox numberis calculated as:Composite redox number=2*(+0.5)+0.4*(−7.0)=−1.8.

According to the present invention, the composite redox number of thefirst glass melt 206 is negative, preferably between −0.05 to −20, andmore preferably between −0.1 to −10. As such, the composite redox valueof the redox active group components is less than zero. In otherembodiments of the invention the composite redox value is equal to zero.

According to various embodiments of the present invention, sulfates, maybe in the form of alkaline earth metal sulfates, such as calcium andmagnesium sulfates, alkali metal sulfates such as sodium and potassiumsulfates, multivalent, and transition metal sulfates, such as zinc,copper and iron sulfates, and a combination thereof. The term “sulfates”encompasses sulfites, bi-sulfite, and bi-sulfates. The solid sulfides,in general may be in the form of any metal sulfides, preferably in theform of multivalent, and transition metal sulfides, such as zinc andiron sulfides. Bounded sulfides from slag, and iron pyrite FeS₂, otherstable metal sulfides, may be used as well. Gaseous hydrogen sulfide isa source of sulfide directly incorporable into the first glass melt 206while in the melter system 300. The slag resulting from someincineration processes (e.g. municipal waste incineration) is aneconomical source of sulfides, with the majority of sulfide being in theform of iron sulfide. Iron pyrite in most cases loses one sulfur atom atrelatively low temperatures, which combines with oxygen and is beingreleased as SO₂ from the batch at a relatively low temperature, e.g.below 800° C.

According to the embodiment of the present invention, whereinessentially all the RAG components 204 are incorporated into the batch200, as a general guideline, the concentrations of several common RAGcomponents 204 in the batch 200 in weight percentage based on the massof the first glass 206 are as follows: sulfates, calculated as SO₄, from0.1 to 5 wt %, sulfides, calculated as S, from 0 to 2 wt %, carbonaceousmaterials, calculated as C, from 0 to 3 wt %, multivalent metal oxidesfrom 0.1 to 20 wt %, and for nitrates/nitrites/nitrides, calculated asN, from 0 to 2 wt %. All or a portion of the RAG components comprisingsulfates and multivalent oxides are preferably incorporated into thefirst glass melt via the batch 200, while other RAG components 204 areincorporated either via the batch 200, and/or via direct addition to themelter system 300, depending on a target composition of the RAGcomponents 204 in the second glass 208.

A transition metal present in the RAG components 204, according to anembodiment of the present invention, is iron. Ferric ion based on itsionic potential is a weak acid in the glass network, meaning that it canparticipate in the glass network in a similar manner with aluminum andboron ions. On the other hand, ferrous ion is a base and has thetendency to donate electrons to the glass network (in particular to theoxygen ions), similarly to calcium and magnesium ions. In terms of glassstructure, ferrous ion acts as a glass network modifier lowering theviscosity of the glass, whereas ferric oxide in most cases becomes apart of the glass network formers, leaving the viscosity practicallyunchanged or slightly higher. In terms of glass making, lowering theviscosity of a glass is normally associated with lowering the meltingtemperature of the glass.

According to one embodiment of the present invention, in order to lowerthe melting temperature of the second glass 208 compared to the firstglass 206, an increase in the concentration of ferrous oxide relative tothe total concentration of iron, as iron oxide in the second glass 208takes place. This is accomplished by in-situ formation of ferrous oxidefrom the iron compounds present in the second glass melt 208 in theprocess of producing hollow glass microspheres. Since the first glassmelt 206 is the precursor to the second glass 208, the relativeconcentration of the iron compounds in the first glass melt is adjustedin the melter system 300 by incorporating the appropriate RAG components204 into the first glass melt 206. The RAG components 204 areincorporated into the first glass melt 206 in the form of gases, vapors,liquids, solids, aerosols and a combination thereof. The incorporationof the RAG components 204 into the first glass melt 206 while in themelter system 300, is carried out by one or a combination of blending,injection, bubbling, spraying, dipping, and stirring in an appropriatesection/compartment of the melter system 300, including the melting zone310, the processing zone 320, discharge zone 330, or in a combinationthereof. In one exemplary embodiment, the first glass melt 206 is meltedunder neutral melting conditions, and as such, the majority of iron inthe first glass melt 206 remains in the ferric form in the glass poolwithin the melting zone 310. At least one reducing RAG component 204 isintroduced into the first glass melt 206 while in the processing zonechamber 320. The reducing RAG component 204 may be selected from avariety of fluids and/or solids, for example an aerosol of carbonparticles in air, a hydrocarbon gas such as acetylene, hydrogen sulfide,hydrogen/nitrogen mixtures, and alike. The reducing RAG component 204 isbubbled, injected, or sprayed into the first glass melt 206 in theprocessing zone 320 of the melter 300 or the discharge zone 330depending on the desired residence time associated with thenon-equilibrium redox reactions involved. By proceeding this way, therelative concentration of the iron compounds in the first glass melt 206is adjusted, and/or residual carbonaceous materials are introduced intothe glass melt 206, as another source of gas formation while producingthe hollow glass microspheres 212.

Accordingly, during thermally processing the glass fragments 210 in step110 to produce the plurality of glass microspheres 212 the concentrationof cationic ferrous iron in the second glass melt 208 is increased.Consequently, the viscosity of the second glass melt 208 is lowered, andso is the melting temperature of the second glass melt 208, bycomparison with the melting temperature of the first glass melt 206.

According to another embodiment of the present invention, to shift thebalance of iron to ferrous oxide, a portion of the sulfate comprised inthe RAG components 204 is converted to sulfide in the first glass melt206. One method to accomplish this shift is by including carbonaceousmaterials, such as carbon, in the RAG components 204, by eitherincorporating them in the batch 200, and/or directly into the firstglass melt 206 in the melter system 300. Carbon, as a part of thecarbonaceous materials, scavenges oxygen primarily from sulfate/sulfitesduring the non-equilibrium redox reactions and in the process forms ironsulfide, CO_(x), and possibly SO₂. In one embodiment elemental sulfur asa part of the RAG components 204 is incorporated in the same manner asdescribed in connection with the carbon example above into the firstglass melt, which results in the formation of iron sulfide in the firstglass melt 206. In another embodiment, iron sulfide and/or iron pyriteas a part of the RAG components 204 is incorporated, in the same manneras described in connection with the carbon example disclosed above intothe first glass melt, which also results in the formation of ironsulfide in the first glass melt.

In accordance with other embodiments of the present invention, similarchemical species to the sulfate-sulfide pair may also be used in thesame manner as described above in connection with the sulfate-sulfidepair. An example is the selenite-selenide pair, SeO₃ ²⁻—Se²⁻.

Exemplarily, the redox reaction involving ferric iron and carbon from acarbonaceous source in the first glass melt 206 is carried out in anon-equilibrium manner to convert less than 80% of the total iron toferrous iron (e.g. ratio of ferrous iron to total iron less than 0.8).To accomplishing the above, the parameters that need to be controlledinclude: the type and concentration of the RAG components to beincorporated into the first glass melt 206, the melting time/residencetime of the first glass melt 206 in the melter system 300, theagitation/bubbling rate and methods applied to the first glass melt 206,and the redox environment of the melter system 300. As a result of thenon-equilibrium redox reactions in the first glass melt 206, thepreferred RAG components 204 reaction products, and chemical speciesthat remain in the second glass 208 preferably comprise at least one ofsulfide, sulfate, carbon compound, and iron. Other oxidizing andreducing chemical species analogous to sulfur compounds, multivalentmetals, and other transition metals can be used in addition or insteadof sulfur compounds and iron for the same purpose.

According to the present invention, the conversion of the first glassmelt 206 into the second glass 208 occurs outside the melter system 300.The conversion occurs when the first glass melt 206 is cooled to formthe second glass 208. Hence, in a broad scope, the glass beingdischarged from the melter system 300 is essentially the first glassmelt 206 being converted to the second glass 208. It is also possible tocharacterize the composition of the second glass melt 208 as beingessentially the same glass composition as being discharged from themelter system 300. Further, the composition of the silicate glassfragments 210 is essentially the same as the composition of the secondglass 208, and wherein the second glass 208 has been fragmented.

In accordance with one embodiment of the present invention, sulfides areintroduced into the batch 200 as part of the RAG components 204. Forexample, iron sulfide is provided as part of the RAG components 204either by introducing into the batch 200 or by forming it in-situ in themelter system 300 by bubbling hydrogen sulfide in the first glass melt206. This is similarly the case as well for ferrous iron, ferric iron,and sulfate/sulfites that may be incorporated in the first glass melt206 as a part of the RAG components 204, to provide the desiredconcentration of iron sulfide, ferrous-ferric ions, and sulfate ions tobe carried over into the second glass 208.

The sulfur in the RAG components 204 that is introduced to the batch 200is provided from one or more of salt cake, gypsum, metal sulfates andbi-sulfates, iron pyrite, slag, flyash, bottom ash, and other wastebyproducts and recycled materials. In addition or alternatively, asulfur source may be introduced into the melter system 300 and beincorporated into the first glass melt 206, to compensate or replace thesource of sulfur in the batch 200. The sources of RAG components to thefirst glass melt 206 according to a broader scope of the presentinvention, may be supplied either to the batch 200, or by directincorporation into the first glass melt 206 while in the melter system300, or both.

According to the present invention, the sulfide to sulfate ratio (e.g.S²⁻/SO₄ ²⁻) in the second glass 208 affects the viscosity of a secondglass melt 208 as related to the ratio of Fe⁺²/Fe (Fe represent totaliron in the glass). The reaction between sulfide and sulfate in thesecond glass 208 provides the gaseous reaction product(s) required toform the hollow glass microspheres 212 in step 110. In the presence ofmultivalent metal cations, such as iron in the second glass 208, as themolar ratio of sulfide to sulfate is increased, the ratio of Fe⁺²/Fe(total) is also increased.

According to the present invention, due to the non-equilibrium redoxreactions taking place in the first glass melt 206, it is possible tocreate iron sulfide in situ co-existing with the sulfate in the firstglass melt 206. The combination of sulfide-sulfate is carried over tothe second glass 208, and it has simultaneously the double advantage ofproviding gaseous reaction products that serve to manufacture hollowglass microspheres 210 from the molten silicate glass fragments 208, andof lowering the melting temperature of the second glass melt 208. Theredox reaction between iron sulfide and sulfate in the second glass melt208 of the silicate glass fragments 210 provides the networkmodifier/flux of ferrous oxide that lowers the melting temperature ofthe second glass 208, as compared to the melting temperature of thefirst glass 206, without sacrificing the chemical durability of theresulting plurality of the glass microspheres 210.

The decomposition of sulfates while melting the first glass 206, withoutand with the presence of carbon is presented in reactions (1) and (2),respectively:SO₄ ²⁻⇄SO₃+O²⁻  (1)SO₄ ²⁻+C- ->SO₂+CO+O²⁻  (2)

As it may be observed above in accordance with the reaction (1), thesulfate ion SO₄ decomposes into sulfur trioxide SO₃ and one oxygen ion(e.g. O²⁻). This reaction occurs in the absence of reducing components.However, when a reducing component, such as carbon, is present in theRAG components 204, the sulfate ion in combination with carbon followsreaction (2), whereby it decomposes into sulfate dioxide SO₂, an oxygenion, and CO. The reaction (2) is generally the rate-controlling step forreaction (1), requiring a reducing component such as carbon. In asituation when an oxidized multivalent metal oxide is also present as apart of the RAG components 204, the oxygen required to oxidize areducing component is primarily supplied by sulfates in the first glassmelt 206 as a primary source, and by the multivalent metal oxide, suchas ferric oxide, as a secondary source. As the melting of the batch 200into the first glass melt 206 progresses, the carbon first reduces thesulfates to gaseous SO₂, and secondly, ferric iron to ferrous iron, andin the process the negative redox ratio of iron (Fe⁺²/Fe total)increases. In the process, depending on the amount of carbon availablein the first glass melt 206, sulfides may also form in the first glassmelt 206 according to following reaction:SO₄ ²⁻+2C- ->S²⁻+2CO₂  (3)

If in the process of the oxidation of carbon, according to the reaction(3), CO is also created, the following reaction takes place, whensulfate ion or other oxygen sources are available in the first glassmelt 206:SO₄ ²⁻+4CO- - ->S²⁻+4CO₂  (4)

Reaction (3) is analogous to reaction (2), with the exception that themolar ratio of carbon to sulfate ion is two times larger. Reactions (3)to (4) are redox reactions presenting the in-situ creation of sulfidesin the first glass melt 206. As previously disclosed, the carbon isprovided by the RAG components 204, included either in the batch 200,and/or incorporated into the first glass melt 206 while processing inthe melter system 300.

The reactions (3) and (4) may be fashioned with iron as the multivalentmetal cation in combination with the sulfide ion. In accordance with thepresent invention, it is possible that other multivalent metal ionspresent in the first glass melt 206 also participate in conjunction withthe ferrous/ferric ions in the above reactions.

It is also possible to incorporate elemental sulfur into the first glassmelt 206, which reacts with the metal ions present in the first glassmelt 206 to produce sulfides. The reactions (3) and (4) abovedemonstrate that carbon is capable to shift the overall valence state ofthe sulfur from sulfate (also sulfite) to sulfide. These reactions occurat a temperature above 900° C. One advantage of incorporating carboninto the first glass melt 206 while in the melter system 300 is that thefirst glass 206 is melted in the melting zone 310 under neutral or infact oxidizing conditions in order to prolong the life of theelectrodes, and contact refractories. The incorporation of carbon issubsequent to the melting process and is carried out in the processingzone 320 of the melter system 300, which in accordance with oneembodiment of the invention is substantially isolated from the meltingzone 310. In the melter system 300, the zones are designed such that thefirst glass melt 206 flows substantially in a one-way direction from themelting zone 310 to the processing zone 320, and from the processingzone 320 to the discharge zone 330. In a situation where a molten saltlayer comprising sulfates is formed over the first glass melt 206, thesulfate layer is reduced to primary SO₂ gas with the incorporation of acarbonaceous RAG component directly into the first glass melt 206 whilein the melter system 300.

According to the present invention, the redox reactions (3) and (4)occurring in the first glass melt 206 are terminated before reachingequilibrium and/or completion. As it was disclosed previously, it isadvantageous to have a combination of sulfate and sulfide (e.g.sulfate-sulfide pair) in the second glass 208 for the purpose ofproviding gaseous reaction products that serve to manufacture hollowglass microspheres 210 from the molten silicate glass fragments 208, andfor the purpose of lowering the melting temperature of the second glassmelt 208. The termination of the redox reactions is achieved bydischarging the first glass melt 206 from the melter and allowing theglass to cool down rapidly. The viscosity of the glass increasesexponentially with decreasing temperature, and as such the redoxreactions come to a stop quickly as the discharged glass is cooled andsolidifies. The extent by which the non-equilibrium redox reactionsadvance towards completion is controlled by the residence time of thefirst glass melt 206 in the melter system 300. Since the redox reactionsare stopped before reaching equilibrium in the first glass melt 206, thenon-equilibrium redox reactions reactants, and the reaction products inthe solidified first glass melt 206 are carried over into the secondglass 208 from which the silicate glass fragments 210 are made. Inaccordance with the present invention, the cooled and solidified firstglass melt 206 is defined or characterized as the second glass 208.

In the thermal processing step 110, the silicate glass fragments 210 arerapidly heated inside the firing furnace to the melting temperature ofthe second glass 208. The following chemical reaction occurs in thesecond glass melt 208:3SO₄ ²⁻+S²⁻- ->4SO₂+4O²⁻  (5)

Reaction (5) requires that both sulfide and sulfate ions are present inthe second glass 208. The cations of the two anionic species may be thesame or different. As disclosed before, iron is an example of a cationfor the sulfide anion, but other multivalent metal cations are as wellwithin the scope of the present invention, such as zinc, copper, andtin. For example, when iron sulfide is present, the reaction (5) is:3SO₄ ²⁻+FeS- ->4SO₂+FeO+3O²⁻  (6)

Reaction (6) can be rewritten as well for ferric sulfide; however, it isbelieved that the majority of the iron sulfide is present as ferroussulfide in the glass second melt 208 in the furnace. As disclosedpreviously, the resulting ferrous oxide behaves like a glass networkmodifier, resulting in the depolymerization of the melt and in loweringthe viscosity of the second glass 208 compared to the first glass 206.The reaction (6) in most cases has an onset temperature of about 1050°C., and a near completion temperature of about 1600° C., with a peakrate at about 1350° C.-1550° C., depending on the furnace atmosphere,and the chemical composition of the second glass 208.

The present invention, as illustrated in the chemical reaction (6), iscapable of providing the double advantage of lowering the meltingtemperature of the second glass 208 (e.g. lowering the viscosity), byin-situ generating fluxing ferrous iron, while simultaneously formingthe ample volume of sulfur dioxide gas that is necessary for thecreation of the plurality of hollow glass microspheres 212 from thesilicate glass fragments 210.

In case that there are more sulfide ions in the second glass melt thanthe stoichiometric ratio of the reaction (5) with respect to the sulfateions present, a portion or all the excess sulfide goes through anoxidization reaction according to reaction (7), as follows:2FeS+3O₂- ->2FeO+2SO₂  (7)

According to the reaction (7), additional expansion gas, e.g. SO₂, andadditional fluxing oxide (e.g. FeO) is produced by an oxidation reactionof sulfide in the second glass melt 208.

An additional source of expansion gas in the second glass melt 208 whilein the furnace is from un-reacted carbon carried over from the firstglass 206 to the second glass 208. The un-reacted carbon reacts with thesulfate, and/or other oxidizers in and out of the molten silicate glassfragments 210 (e.g. second glass melt 208). The reaction is similar tothe reaction (2), and results in forming SO₂, and CO_(x) (1≦x≦2). Theoxygen from the combustion air inside the furnace is an external sourceof oxidizer.

The physical reboil of SO₂/SO₃ which may occur in the furnace at thesame time with reaction (7) also adds to the total volume of gas createdand available for further expanding the silicate glass fragments 210 tohollow glass microspheres 212. The physical reboil is triggered in thesecond glass melt 208, by exceeding the solubility limitations of thesulfur oxide gases in the second glass melt 208.

In accordance with another embodiment of the present invention, apredetermined amount of carbon, e.g. residual carbon, is allowed toremain in the first glass melt 206. This is carried out preferably bydirectly incorporating a carbonaceous RAG component 204 in the firstglass melt 206, while in the melter system. Optionally, this can beaccomplished via residual carbon carried over from the RAG components204 that were included in the batch 200. The advantage of havingresidual carbon is that this residual carbon consumes any remainingsulfate, according to reaction (3), thus creating CO₂ gas that isutilized further for the expansion of the silicate glass fragments 210.In addition, any sulfide formed, after the exhaustion of the residualcarbon, is oxidized by oxygen in the furnace to provide additional SO₂also being utilized for the further expansion of the silicate glassfragments 210 to hollow glass microspheres 212. Finally, when bothferric and ferrous iron are present in the melt of the second glass 208of the silicate glass fragments 210, residual carbon promotes thereduction of ferric iron to ferrous iron and the creation of CO₂ gas inthe process. Again, the created CO₂ gas is a source of gas available toexpand the silicate glass fragments 210 to hollow glass microspheres212. Since the majority of iron would be in the form of ferrous iron, asignificant reduction in the melting temperature of the second glass 208is attained compared to the melting temperature of the first glass 206.Carbon carry over into the second glass 208 is possible, because of theability to incorporate carbon at the stage of the melt processing in themelter system 300. As such, the carbon impregnated first glass melt 206,resides only a short time in the melter system 300 before beingdischarged and cooled. As a result, the carbon is not fully consumed inthe first glass melt 206 and is carried over into the second glass 208.This is another example of a non-equilibrium redox reaction occurring inthe first glass melt.

Providing a first glass melt 206 with any other short lived chemicalspecies while in a molten state is accomplished by impregnating thefirst glass melt 206 in the processing zone, and/or discharge zone ofthe melter system 300 with the desired short lived chemical species.This allows the chemical species to be carried over to the second glass208. The impregnation is achieved by incorporating a desired chemicalspecies, such as for example carbonaceous materials, into the firstglass melt 206 while in the melter system 300. As previously disclosedthe incorporation is realized by various methods including bubbling orinjecting the chemical species in the melter system 300 in such zoneslike the processing zone 320, and the discharge zone 330 of the melter.The chemical species will undergo a targeted reaction when the secondglass is reheated and is melted.

The sulfate redox reactions involving carbon (e.g. added as a part ofthe RAG components to the batch 200 and/or in the form of gaseous,liquid, solid carbonaceous materials and aerosols bubbled and/orinjected into the first glass melt 206) are influenced by the relativeconcentration of carbon to sulfates, the reaction time, and the melttemperature.

In accordance with the present invention, direct conversion of sulfatesto sulfides is achieved in the first glass melt 206 while in the meltersystem 300 by incorporation of a carbonaceous chemical species such ascarbon into the first glass melt 206.

In the case that carbon is not totally consumed in the first glass melt206 due to the non-equilibrium redox reactions, as disclosed previously,a portion of the unreacted carbon will be carried over to the secondglass 208 as the residual carbon.

In accordance with the present invention, and the above disclosure,there is more than one source of gas formation within the second glassmelt 208 during the expansion of the silicate glass fragments 210 to thehollow glass microspheres 212. Thus, it is possible to increase ordecrease the volume of gas created during the expansion of the silicateglass fragments 210 in such a way to obtain the desired average particledensity of the corresponding hollow glass microspheres 212. As disclosedabove, as the concentration of sulfides and residual carbon areincreased in the second glass 208 via non-equilibrium redox reactionsinduced in the first glass melt 206, a larger volume of expansion gas isgenerated in the second glass melt 208 resulting in lowering theparticle density of the hollow glass microspheres 212 to very lowvalues, e.g. below 0.4 g/cm³. According to one aspect of the presentinvention, the combined volume of gas generated in the second glass melt208 causes the silicate glass fragments 210 to expand, and is due tomore than one gas forming chemical species simultaneously and more thanone gas generation mechanisms generating gas in the molten silicateglass fragments 210 en-route to the hollow glass microspheres 212.

As the ratio of carbon to sulfate increases in the RAG components 204,under equilibrium conditions, more sulfate is consumed to form sulfidesand/or SO₂. However, depleting the sulfate completely from the firstglass melt 206, and consequently from the second glass 208 is notrecommended, otherwise reaction (5) might not take place in the secondglass melt 208. Henceforth, the non-equilibrium redox reactions areimportant to take place in the first glass melt 206.

As disclosed previously, and in accordance with the present invention,the volume rate of gases generated in the second glass melt 208 withinthe silicate glass fragments 210 is in a direct relationship with theparticle density of the resulting plurality of hollow glass microspheres212, e.g. the higher gas generation volume rate, the lower particledensity.

The advantages provided by the method of the present invention areevident, as the amount of gas created during the expansion of thesilicate glass fragments 210, employed for the creation of the glassmicrospheres 212, is precisely controlled by controlling theconcentrations of sulfides, sulfates, and residual carbon in the secondglass 208. In addition, the amount of ferrous iron oxide created in thesecond glass 208 due to redox reactions as disclosed previously affectsthe melting temperature of the second glass 208 and as such the meltingtemperature of the silicate glass fragments 210 in step 110.

In the event that either or both thermal and physical reboils phenomenaare also present, the firing temperature and the residence time in thefurnace are also adjusted to control the total volume of gas generatedin glass melt of the second glass 208 by measuring the average particledensity of the hollow glass microspheres 212.

One method of evaluating the necessary process parameters, such as thetypes and amounts of RAG components 204, the residence times in themelter system 300 and the firing furnace, melting and firingtemperatures, requires measuring at least one of the particle density,the mechanical strength, the chemical durability, and other physical andchemical characteristics of the glass microspheres 212.

For example, one measurement data set is appropriately arranged (i.e.graphically or tabulated) to show the results of measuring the particledensity of the glass microspheres 212 as a function of the firingtemperature for a given residence time inside the firing furnace. Asecond set of data is arranged to show the results of measuring theparticle density of the glass microspheres 212 as a function of theresidence time for a given firing temperature. Another example isrelated to the hydrostatic pressure and/or crushing strength of thehollow microspheres 212 as a function of particle density. Other suchrepresentations may be as well performed apart from the ones exemplarilyspecified above, to aid with the evaluation of the necessary processparameters and to learn regarding any necessary changes in saidparameters.

Exemplary for a desired hydrostatic pressure rating and/or crushingstrength of the glass microsphere 212, a corresponding targeted particledensity is determined from the data representation. To affect theparticle density of the glass microspheres 212, the important processingparameters are the residence time in the heated zone of the furnace, thetemperature of the heated zone of the furnace, and the volume of gasbeing generated in the second glass melt contained in the moltensilicate glass fragments 210 while in the furnace. In practice, theresidence time is not significantly variable, since the length of thefurnace is fixed. The linear velocity of the silicate glass fragments210 inside the furnace can be varied some, as the volumes of thecombustion air and gas entering the furnace for a given solid loading,may vary but not significantly. Optionally the firing temperature may bevaried, which affects the volumes of the combustion air and gas.However, the preferred option in accordance with the invention is toaffect the volume of gas being generated within the second glass melt208, by adjusting the types and concentration of the RAG components 204in the melter system 300 as discussed in detail previously in connectionwith the capability to manufacture glass microsphere 212 with varyingdensities.

As previously discussed, the plurality of sulfide compounds are eitherincluded as part of the RAG components 204 entering the batch 200 fromwhich the first glass melt 206 is created, or alternatively are formedin-situ in the first glass melt 206 while residing inside the meltersystem 300. In accordance with the present invention, the concentrationof total sulfides, calculated as S²⁻ in the second glass 208 is from0.001 to 2 wt % based on the mass of the second glass 208.

In accordance to the present invention, the molar fraction of sulfide(as S²⁻) over total sulfur (S²⁻+SO₄ ²⁻) in the second glass 208 isgreater than zero.

The atmosphere within the furnace employed for heating and expanding thesilicate glass fragments 210, in accordance with the present invention,is controlled to be either neutral, oxidizing, or reducing. When thefurnace is operated under neural to mildly reducing conditions therelative concentration of thermal NOx in the flu gases is decreased,which is environmentally advantageous. Another advantage of the presentinvention is due to having the ability to lower the melting temperatureof the second glass 208 compared to the first glass 206. Yet anotheradvantage of the present invention is the ability to generate gas in thesecond glass 208 from multiple sources. All the advantages above lead tothe ability of lowering the firing temperature requirements for thesecond glass that in turn results in improving the fuel efficiency ofthe manufacturing process, and hence the ability of economicallymanufacturing high quality hollow glass microspheres 212.

The sulfide compounds of the RAG components 204 include both syntheticand mineral compounds of sulfides. According to the present invention,in addition to or instead of sulfides, selenides, antimonides,bismuthinides, and sulfosalts may also be used, but they are normallymore costly than the synthetic and mineral compounds of sulfidescontaining S²⁻. Examples of the sulfide compounds that are usedaccording to the present invention are one or a combination of acanthiteAg₂S, chalcocite Cu₂S, bornite Cu₅FeS₄, galena PbS, sphalerite ZnS,chalcopyrite CuFeS₂, pyrrhotite FeS, millerite NiS, pentlandite(Fe,Ni)₉S₈, covellite CuS, stibnite Sb₂S₃, pyrite FeS₂, molybdeniteMoS₂, and other metal and transition metal sulfides. Iron sulfide, withthe general formula Fe_(1-x)S, is one sulfide compound to be usedaccording to one embodiment of the present invention, wherein x variesfrom zero to 0.5. Iron sulfide, for example, in the form of pyrite, isreadily commercially available at relatively low cost. Another source ofiron sulfide is from vitreous, semi-vitreous, or crystalline industrialbyproducts such as incineration slag, incineration ash, bottom ash, andflyash. Ferric sulfide is also acceptable.

In accordance with one embodiment of the present invention, all or aportion of the materials that constitute the batch 200 are derived fromrecovered materials. As disclosed earlier in this document, the“recovered materials” are waste materials, either of hazardous ornon-hazardous nature. Converting non-hazardous recovered materials tohollow glass spheres provides a highly value added product, whilepreserving natural resources, by decreasing the demand for mined rawmaterials. Exemplarily, asbestos containing waste materials, inaccordance with the present invention are melted as a part of the batch200 into the first glass 206 in the melting zone 310. Any adjustments tothe RAG components are carried out either via batch 200 and/or insidethe melter system 300 such as in the melting zone 310, the processingzone 320, and the discharge zone 330. In this way, not only a hazardouswaste material is safely vitrified, but also the resulting vitrifiedmaterial forms a second glass 208, which is suitable to be converted tohigh quality glass microspheres 212. The embodiment of the inventiondisclosed above for the asbestos containing waste materials is equallyapplicable for other waste materials, such as incineration ash,radioactive waste materials, and any other vitrifiable waste materials.

In accordance with one embodiment of the present invention, a vitrifiedwaste material that has a combination of RAG components and/or RAGcomponents reaction products, such as at least one sulfur compound, anda multivalent metal, is used directly as the second glass 208 from whichsilicate glass fragments 210 are made. Accordingly, the vitrified wastematerial is pulverized and sized in step 108, forming the plurality ofsilicate glass fragments 210. The resulting silicate glass fragments 210are heated in step 110 to form glass microspheres 212, which in thiscase are directly produced from pulverization of a vitrified wastematerial. Exemplary vitrified waste materials to be used as the secondglass 208 are: vitrified asbestos waste materials, vitrified hazardouswaste materials, vitrified radioactive waste materials, vitrifiedincinerated municipal waste materials, vitrified incineration ash, andvitrified medical waste materials.

Converting hazardous materials into non-hazardous recovered materials,and then into glass microspheres provides better handling, moreefficient storing, and the possibility of reuse of the recoveredmaterials. Examples of a non-hazardous (land fillable) industrialbyproducts used are fly ash, bottom ash, and in some cases incinerationash. Examples of hazardous materials converted into non-hazardousrecovered materials and consequently into glass microspheres, areasbestos containing waste materials, and medical/municipal wastematerials that are vitrified into essentially non-hazardous glassymaterials. Another example of a hazardous industrial byproduct isvitrified nuclear waste that despite being considered radioactive, theradioactive isotopes contained in it, are securely fixed into themolecular structure of the glass, resulting in glasses that arechemically very durable and physically highly stable. The vitrifiednuclear waste glass is used as the second glass 208 in accordance withthe present invention to manufacture radioactive glass microspheres.Most of the vitrified low level nuclear glasses contain RAG components204, in the form of iron oxide, and sulfur compounds. The glassmicrospheres 212 are essentially solid when there is not sufficient gasforming RAG components 204 present. On the other hand, the microspheresare hollow when there is sufficient gas forming RAG components 204present. The resulting glass microspheres find uses in manyapplications, including radiation source miniaturization, medicalapplications, etc.

According with an embodiment of the present invention, the vitrifiedhazardous waste materials are used instead of batch 200 to create thefirst glass 206. In certain cases when sufficient RAG components 204 (orRAG reaction products) are already present in the vitrified hazardouswaste materials, they are treated as the second glass 208, and furtherprocessed in accordance with the steps 108, 110, and 112 to manufacturecorresponding glass microspheres. The resulting glass microspherescreated in accordance with this embodiment of the invention, find use inmany applications that require an inexpensive, and high performancefiller particles for composites. Another example of a post consumernon-hazardous consumer byproducts that may be used instead of or inaddition to the batch 200 is incineration ash resulting fromincinerating waste materials.

The method 100 of manufacturing a plurality of glass microspheresproposed by the present invention is discussed in more detail inconnection with various example embodiments described herewith. Thefollowing examples demonstrate exemplary embodiments of the presentinvention at least insofar the method of manufacturing a plurality ofglass microspheres.

EXAMPLE 1

This example describes an embodiment of the present invention in whichfly ash is used as a part of the batch 200. Additionally, the presentexample illustrates the embodiment of the present invention wherein theRAG components 204 are intrinsic and/or integral to the SGP rawmaterials 202.

Fly ash is an industrial byproduct that falls into the category ofmaterials defined herein as “recovered materials”. ASTM C618 providestwo types of fly ash classifications: Class F: SiO₂+Al2O3+Fe2O3≧70%, andClass C: SiO₂+Al2O3+Fe2O3≧50%. All in wt %.

The RAG components in fly ash comprise unburned carbon, which can varyfrom 0.2 to as high as 3.5 wt %, in addition to iron oxides, and sulfurcompounds. Iron oxides are almost always present in fly ash, mostly inthe form of magnetite (FeO+Fe₂O₃) and sulfur in the forms of sulfates,sulfites, or sulfides.

A typical class F fly ash, has less sulfur than a class C fly ash. Theinitial content of sulfur as sulfate in the flyash is usually less than1 wt % depending on how much sulfur has been scrubbed off from the flugas via a flu gas desulfurization unit. Without a significant scrubbingaction, the amount of sulfate may be around 0.5%, and the molar ratio ofunburned carbon to SO₃ varies from less than one to as much as 10.

The wt % of the major oxides in the class F fly ash are: SiO₂ 35-65 wt%, Al₂O₃ 20-45 wt %, FeO—Fe₂O₃ 3-12 wt %, and CaO 1-10 wt %. In thisexample, iron oxide(s), sulfur compounds, and unburned carbon areconsidered part of the RAG components 204, despite of being constituentsof the fly ash that is part of the SGP raw materials 202. Therefore, theRAG components 204 are intrinsic (integral) to the SGP raw materials202.

According to one embodiment of the present invention, deficiencies inthe RAG components are compensated by dosing the appropriate amount of adeficient component to either the batch 200, and/or the first glass melt206 while in the melter system. In contrast, if the RAG components arealready part of the fly ash, any RAG component deficiencies arecompensated by adding extra SGP raw materials 202 to the batch until theconcentration of a particular RAG component is brought within thedesired range in the batch 200. The resulting batch 200 may also requirethe addition of those RAG components 204 that may have become deficientdue to the addition of additives. A batch 200 is prepared with Fly ash(type F) 40-80 parts, silica sand 20-30 parts, gypsum 1-3 part, and 0-25parts of one or a combination of lime stone, dolomite, salt cake,soda-ash, Pyrex glass cullet, a soda lime glass cullet, and potash. Theresulting batch 200 has a composition that falls within the prescribedrange of composition for the first glass melt 206 disclosed earlier. Thecomposite redox number of the batch 200 is within the range of −0.1 to−10.

Next, the batch 200 is blended prior to being melted in an electricmelter system 300. The residence time in the melter system 300 is about5 hours. The melter system 300 comprises a primary melting zone 310,where a glass melt pool is created at an average temperature rangingfrom about 1300° C.-1450° C. as measured in the molten glass between theelectrodes. The melter is operated with a cold cap over the molten glassin the primary melting zone 310. The melter system 300 has a processingzone 320, and a discharge zone 330 comprising a side airlift assisteddischarge port. Bottom gravity assisted discharge ports are provided inmelting zone 310, and the processing zone 320 to empty the molten glassinventory of the melting zone, and the processing zone when needed insuch occasions like repair, and scheduled shut down periods. In case amolten metal layer formed at the bottom of the either zone, the moltenmetal layer may be discharged through the bottom discharge ports. Themelter electrodes housed in the primary melting chamber 310, comprisemolybdenum alloyed with zirconium oxide, and are powered with a threephase AC power supply.

As the batch 200 melts into the first glass 206, a portion of theunburned carbon in the ash oxidizes by oxygen in air forming CO₂ withinthe cold cap, and near the molten glass interface. As the meltingprogresses from the cold cap to the glass pool, another portion of theunburned carbon reacts with sulfate according to the redox reaction (2),forming SO₂ gas. The remaining unburned carbon as it comes into intimatecontact with the first glass melt 206, reacts with sulfate according tothe redox reactions (3) and (4), forming a plurality of reactionproducts that include iron sulfide. The non-equilibrium redox reactions(3) and (4) are terminated before reaching the equilibrium state byeffectively discharging the first glass melt 206 from the melter system300. Injection ports accessible through the plenum of the processingzone of the melter system 300 allow the delivery of the additional RAGcomponents 204 to be directly incorporated into the first glass melt 206while in the melter system 300. Pressurized air assisted graphite spraynozzles are provided to deliver graphite powder or any other gaseous orliquid RAG components 204 into the melter system 300. The capability ofbeing able to incorporate directly the RAG components 204 into the firstglass melt 206, while in the melter system 300 allows for controlling anaccurate balance/amount of gas forming species that are carried over tothe second glass 208. The discharged glass is cooled rapidly over alarge steel plate forming the second glass 208. Because of terminatingthe redox reactions before reaching equilibrium in the melter system300, a predetermined mixture of sulfate and sulfide coexists in thesecond glass 208. The resulting second glass 208 is then pulverized instep 108 to an average particle size of about 60-80 microns forming thesilicate glass fragments 210.

Next, the silicate glass fragments 210 are suspended in a combustion airstream entering a burner system provided inside a firing furnace at anaverage rate of approximately 1 kg of particles per 1 m³ of air. Thefiring furnace is an upward vertical gas fired cylindrical furnace. Aco-concentric burner fueled with natural gas is used and the injectionvelocity at an axial upward direction is set to be about 2-10 m/s. Theamount of combustion air supplied to the furnace is adjusted to be closeto the stoichiometric air-gas ratio in such a way to have a relativelyneutral ambient atmosphere surrounding the silicate glass fragments 210.In the combustion zone of the furnace and at an average firingtemperature of about 1300-1550° C. (as measured in the combustion zone),the silicate glass fragments 210 melt and expand to form the hollowglass microspheres 212. Outside ambient air is allowed to enter thefurnace near the top after the combustion zone, resulting in a sharptemperature drop and immediate cooling of the microspheres. The furnaceis under a mild vacuum, and glass microspheres 212 are collected in ahot cyclone. The overall residence time in the furnace averages to lessthan 4 seconds.

It is of note the glass microspheres 212 are manufactured in accordancewith an embodiment of the method of the present invention that comprisesa glass melting step in which non-equilibrium redox reactions areprovided by a redox active group component, followed by a glassremelting step, capable of self-generating gas by at least one redoxreaction to form a plurality of hollow glass microspheres.

It is also of note that in accordance with an embodiment of the methodof the present invention, RAG components are incorporated directly intoa glass melt. The method takes advantage of the non-equilibrium redoxreactions occurring in the glass melt upon incorporation of the RAGcomponents. Accordingly, a glass melt with a desired composition isformed inside the multizone melter system. The melter system comprisesat least a melting zone, a processing zone, and a discharge zone havingdischarge means to discharge the molten glass at will. The glass melt istransferable from the melting zone to the processing zone essentially ina one-way forward movement, and not vice versa. As such, the glass meltcan move from the melting zone to the processing zone, but not in theopposite direction. In the processing zone of the melter system, the RAGcomponents are incorporated into the glass melt, and are uniformlydispersed into the glass melt. The glass melt from the processing zone,upon incorporation of, or impregnation with the RAG components, isdischarged from the melter system. The discharged glass upon cooling isfragmented. The RAG components in the glass fragments upon heating andremelting in the furnace go through predetermined redox reactions andform a plurality of gases. The plurality of gases is entrapped in themolten glass fragments and as a result the molten glass fragmentsexpand, and hollow glass microspheres are formed. Therefore, tosummarize, the glass microspheres have been formed, in accordance withthe above example by a method comprising the following steps: forming abatch, melting the batch into a first glass melt in a melting zone ofmultizone melter system, transferring the first glass melt from amelting zone to a processing zone, impregnating the first glass meltwith RAG components while in the melter system, discharging and coolingthe first glass melt from the melter system to form a second glass,pulverizing the second glass into glass fragments, heating and meltingthe glass fragments, expanding the molten glass fragments into hollowglass microspheres by generating and trapping gas via the RAG componentsin the second glass melt, and cooling the hollow glass microspheres.

It is of note that no art reference discloses utilizing industrial wasteor recycled byproducts as raw materials to melt a glass precursor fromwhich silicate glass fragments suitable for making hollow glassmicrospheres are manufactured by the process outlined above.

EXAMPLE 2

In accordance with a further example of the present invention, amunicipal waste incineration-ash, and/or a medical wasteincineration-ash, is used as a part of the SGP raw materials. Silicaflour is added in order to increase the silica content of the compositebatch 200. As a part of the RAG components 204, gypsum is added to thebatch 200 to adjust the sulfate content to achieve a prescribed chemicalcomposition for the first glass melt 206. The resulting batch 200 ismelted in the same type melter system that is employed in the Example 1.Hydrogen sulfide, with and without a carbonaceous RAG component 204,such as graphite is incorporated into the first glass melt 206 while inthe melter system 300, in order to control the gas volume generated inthe second glass melt 208 via the redox reactions while in the furnace.The first glass melt 206 is discharged from the melter system 300,cooled, and pulverized to form the silicate glass fragments 210. Thenewly formed silicate glass fragments 210 are reheated in the firingfurnace to about 1300-1550° C. to form the glass microspheres 212. Theaverage residence time in the furnace is less than 4 seconds. Inaccordance with this example, a value added product is made fromotherwise waste materials that in most cases are regulated and may notbe land filled in unregulated landfill areas.

EXAMPLE 3

In yet another example of the present invention, a vitrified low levelradioactive waste material is treated as the second glass 208. Thesecond glass 208 is a borosilicate-based glass. The solid pieces of thesecond glass 208 are pulverized and screened to obtain the desiredsilicate glass fragments 210. The silicate glass fragments are fired ina firing furnace that has suitable off gas treatment capabilities forradioactive gaseous and particulate emissions. The firing temperature isset around 1200-1400° C. The resulting radioactive glass microspheres212 are chemically durable and stable. The radioactive glassmicrospheres may be used as a radiation source, for example in medicalapplications. In addition, the radioactive glass microspheres can bereused, and repackaged easily as a flowable solid material.

EXAMPLE 4

In accordance with another example of the present invention, value addedglass microspheres are produced from the asbestos containing wastematerials. The asbestos containing waste materials normally containgypsum and iron wires (i.e. metal mesh screen) in their makeup (e.g.examples of intrinsic RAG components). The asbestos containing wastematerial of the present example is a part of the SGP raw materials, andincluded in the batch 200. Silica flour is added to the batch 200 tobring the silica level of the first glass melt 206 within the prescribedrange in accordance with the present invention. No additional RAGcomponent is added to the batch 200. Next, the batch 200 is melted in asimilar melter system 300 employed in the Example 1. A mixture ofhydrogen and nitrogen gas is incorporated into the first glass melt viabubbling into the processing zone 320 of the melter system 300 to adjustthe balance of sulfide-sulfate in the first glass melt 206, andconsequently in the second glass 208 in accordance with the presentinvention. The first glass melt 206, which represents the vitrifiedasbestos waste containing materials upon cooling, forms the second glass208, and is ground-up to form the silicate glass fragments 210. Thesilicate glass fragments 210 are reheated in the firing furnace to about1300-1500° C. to form glass microspheres 212. The average residence timein the furnace is less than 4 seconds. Further redox adjustments arecarried out by injecting graphite powders into the first glass melt toproduce hollow glass microspheres with an average particle density ofless than 1 g/cc. This example also illustrates the embodiment of theinvention wherein an elemental multivalent metal (e.g. iron) is used asone of the RAG components 204.

EXAMPLE 5

This example illustrates an embodiment of the present invention whereinglass raw materials are used as SGP raw materials 202, in addition tothe RAG components 204 in making up the batch 200.

The SGP raw materials 202 comprise in accordance with the presentexample silica flour (or equally ground quartz), kaolin, dolomite (ofparticulate dimensions of under 200 mesh), potash feldspar (orthoclase),and soda ash. The RAG components 204 in accordance with the presentexample comprise iron oxide (rust), gypsum (of particulate dimensionsunder 200 mesh), and carbon (powdered graphite). The batch 200 is formedwith varying concentrations of ingredients of the SGP raw materials 202as follows: silica sand, 10-40 parts, kaolin, 30-60 parts, dolomite,20-40 parts, potash feldspar, 10-15 parts, soda ash 2-3 parts, and theRAG components 204.

The RAG components 204 exemplarily comprise iron oxide (rust), 1-5parts, and gypsum, 2-5 parts. Carbon at a total level of 0.1-2 parts isadded both to the batch 200, and is incorporated directly into the firstglass melt 206 while in the melter system 300. The composite redoxnumber of the first glass 206 is less than zero.

After forming the batch 200 by combining the above enumerated SGP rawmaterials 202, and the RAG components 204, the batch 200 is melted in amelter system 300. The melting of the batch 200 in the melting zone ofthe melter 310 to form the first glass 206 takes between 5-10 hours atan average temperature between 1300-1450° C. as measures in the meltpool.

As with the previous examples, a melter 300 is preferably operated witha cold cap over the molten glass in the primary melting zone 310. Carbonis delivered to the first glass melt 206 in the form of graphite powderentrained in pressurized air, with and without hydrogen sulfide. Themixture is bubbled into the first glass melt 206, while in theprocessing zone 320, to induce non-equilibrium redox reactions leadingto a desired balance between sulfide and sulfate ions in the first glassmelt 206, and consequently the second glass 208. In the above process,residual carbonaceous materials are provided in the first glass melt 206when desired. Hydrogen sulfide and carbon are effective means to adjustthe particle density of the hollow glass microspheres 212. As the firstglass melt 206 enters the discharge zone 330, the non-equilibrium redoxreactions have reached the desired non equilibrium state and the firstglass melt 206 is discharged from the melter 300 via a melt dischargetrough. The discharged glass is cooled rapidly over a large steel plateforming the second glass 208. Because of terminating the redox reactionsbefore reaching equilibrium in the melter system 300, by discharging andrapidly cooling the molten glass, a mixture of sulfate and sulfidecoexist in the second glass 208. The resulting second glass 208 is thenpulverized in step 108 to an average particle size of about 60-80microns forming the silicate glass fragments 210.

Next, the silicate glass fragments 210 are converted into hollow glassspheres 212 by following a procedure similar to the procedure outlinedin the Examples above. The resulting hollow glass microspheres 212 havea structure similar to the one schematically represented in FIG. 2, thatwill be described in detail bellow. The average particle density of theobtained hollow glass microspheres 212 is below 1 g/cm³.

EXAMPLE 6

Example 6 illustrates an embodiment of the present invention whereincarbon is added to the first glass 206 while in the melter system 300.In accordance with this embodiment of the present invention the SGP rawmaterials 202, are the ones used as discussed above in connection withExample 5, are combined with the RAG components 204 exemplarilydiscussed above in connection of the Example 5, except carbon, to formthe batch 200. The batch 200 is subsequently melted in the melting zone310 of the melter system 300. A graphite powder spray, in combinationwith pressurized air is used to inject fine graphite powder into thefirst glass melt 206 while in the melter. As an alternative, fine powdergraphite or coke, or carbon black (with an average particle size of lessthan 10 microns), is entrained in a gaseous, vapor, or liquid carrier ata loading such that it is dispersed uniformly into the first glass meltwhile in the melter system 300, for example by injection or sprayinginto the molten glass. The first glass melt 206 is discharged andfurther processed in accordance with the method of the presentinvention, and as disclosed above as well in connection with Examples 1to 5, to manufacture the glass microspheres 212.

EXAMPLE 7

This example illustrates an embodiment of the present invention whereiniron is added as part of the recycled waste byproduct to the glassforming constituents of the SGP raw materials 202 of the Example 5.Calcined red mud (from the aluminum smelting process), at a level of15-25 parts, is included in the SGP raw materials 202. As a result,there is no longer a need to add soda ash, since the calcined red mudcontains about 5-8 wt % sodium oxide. Additionally, iron oxide (rust) isno longer added, since red mud contains about 45-55 wt % iron oxide.Subsequently, the first glass 206 is melted, and converted to the secondglass 208 as outlined in connection with either one of the examples 5,and 6 above. The resulting second glass 208 is pulverized to form thesilicate glass fragments 210, which are then converted to hollow glassmicrospheres 212 in accordance with the embodiments of the method of thepresent invention. The resulting hollow glass microspheres 212 areprecursor for production of ferrimagnetic hollow glass ceramicmicrospheres. This is achieved by heat-treating the glass microspheres212 at a temperature below the deformation temperature of themicrospheres. Upon heat treatment, and due to formation of nano-sizemagnetite crystals that are homogenously dispersed in the glass wall ofthe microsphere 212, glass-ceramic microspheres with strongferromagnetic properties are produced. By increasing the concentrationof iron in the first glass 206, for example via the addition of more redmud in the raw materials 202, glass microspheres with iron oxide contentof 10-20 wt % are obtainable.

The present invention enables the production of highly durable andstrong hollow glass microspheres at a high throughput using inexpensiveraw materials. The throughput is high because the combined residencetime in the melter system 300 and the firing furnace is less than 12hours, and preferably 5 hours or less. This makes the production processto be highly sustainable (energy efficient) since it is possible to takeadvantage of fast manufacturing methods. Another advantage of the methodof the present invention is that the RAG components 204 inherently existin the many forms of the recovered materials, thus a relatively low costfor the raw materials can be realized. This makes possible theproduction of an eco friendly product, by utilizing industrial wastebyproducts and converting them into high value added products.

According to the embodiments of the present invention, the glassmicrospheres 212 manufactured according to the methods of the inventionare used in at least one of the following applications: in the oil andgas industry, as light weight fillers for various composites, inbuilding materials, in the automotive and aeronautic industries, in themedical industry, integrated in paints and road signs, and as functionalfillers for various composite materials. Additionally, the glassmicrospheres manufactured according to the method of the presentinvention are suitable to be subjected to various surface treatments andmodifications to impart desired surface functionalities to the resultingmicrospheres. Examples are coloring the surface, coating the surfacewith various functional coatings such as magnetic, electricallyconductive, light reflective, self-cleaning, and attaching surfacefunctional groups to the microsphere surface such as ionic chemicalspecies, organo-functional groups such as silanol functional group, andhydroxyl functional groups. Hydraulic fracturing involves pumpingfracturing fluids into an oil or gas well at high pressure to createfractures in the rock formation that allow oil or gas to flow from thefractures to the wellbore. The fracturing fluid is normally water based,and comprises propping particles (proppants) and other additives. Themicrospheres 212 of the present invention that have very high crushingstrength above 5000 psi, and preferably above 10,000 psi are excellentcandidates as propping particles to keep fractures open once they areproduced under high pressure.

Therefore, an embodiment of the present invention, also comprises acomposite product, comprising a combination of the plurality of glassmicrospheres manufactured in accordance with the present invention, andat least one of a plurality of polymer matrices, a plurality ofcementiteous matrices, a plurality of fluid matrices, a plurality ofsolid matrices, a plurality of fiber containing matrices, and aplurality of metal matrices.

Due to the superior acid and alkaline resistance of the glassmicrospheres 212 manufactured according to the present invention, theglass microspheres can be safely used in high alkalinity environments,such as in cements and concretes, and in hydraulic fracturing liquidsthat are acidic. The cements may comprise one or a combination ofPortland cement, aluminous cements, lime cements, magnesium basedcements, calcium sulfo-aluminate cements, phosphate cements, gypsum,geopolymers, and others. The glass microspheres 212 manufacturedaccording to the present invention are also used in acidic environments,such as in acidic hydrofracking fluids. The glass microspheres 212 ofthe present invention can be coated and/or surface treated with avariety of coating materials and surface treatment agents and equipment.The coating materials comprise inorganic coating materials, organiccoating materials, and a combination thereof. The coating is applied tothe external surface of the microspheres 212 to impart specific surfaceproperties to the microspheres 212. Examples of such coatings arecolorants, electrically active, magnetically active coating, reflective,chemically active, mechanical property enhancing, and biologicallyactive. The surface treatments include: silanization, passivation,activation, ion exchange, etc.

Cements or other mediums containing the glass microspheres of thepresent invention are used in applications related to the oil and gasindustries, such as in oil and gas well drilling cement, oil and gaswell cementing casing, and oil and gas fracking including but notlimited to shale oil fracking, and hydraulic fracking. Since in thesetypes of applications the utilized microspheres are required to haverelatively high hydrostatic pressure rating, normally above 1,000 psiand as high as 20,000 psi, the glass microspheres of the presentinvention are particularly suitable for these applications.

Referring now to FIG. 2, FIG. 2 comprises a schematic illustration of aglass microsphere produced in accordance with the methods of the presentinvention.

The glass microsphere manufactured according to the various embodimentsof the present invention comprises in its most general embodiment aplurality of glass walls, and a plurality of hollow spaces, theplurality of glass walls enclosing the at least one of the plurality ofhollow spaces. The plurality of glass walls comprises a second glass.The second glass is formed by further processing a first glass melt. Thefirst glass melt is formed by melting a batch comprising at least one ofa plurality of raw materials. The plurality of RAG components present inthe first glass melt and a melt of the second is capable of providing atleast one of a plurality of redox reactions and a plurality of events inthe first glass melt and the melt of the second glass, thereby creatingthe glass microsphere.

In accordance with one embodiment of the present invention, the glassmicrosphere manufactured according to the embodiments of the presentinvention comprises a single or a plurality of glass walls, and a singleor a plurality of void spaces defined by said wall or walls. The termsof “glass microsphere(s)” and “hollow glass microsphere(s)” areinterchangeably used throughout this document to refer to a structurethat comprises one or a plurality of enclosure glass walls, forming aplurality of interior and/or exterior (outer) partition walls,surrounding at least one or a plurality of hollow spaces.

FIG. 2 comprises representation of a glass microsphere produced inaccordance with the methods of the present invention. In accordance withFIG. 2, the exemplary hollow glass microsphere 20 comprises a sphericalouter glass wall 22 and a substantially enclosed cavity or void 24defined by the outer glass wall 22. The configuration of the sphere 20in FIG. 2 resembles the general configuration of harvested cenospheresfrom coal burning fly ash. The outer glass wall 22 comprises ahomogenous second glass 208.

A hollow glass microsphere as shown in FIG. 2 has a specific strength,which is defined by the crushing strength of the microsphere divided bythe particle density of the microsphere in the range of about 40-340MPa/(g/cm³), where MPa is mega Pascal. The specific strength over avalue of 100, normally represents glass microspheres having a particledensity over 0.4-0.5 g/cm³. Also, the smaller the average particle sizeis, the higher the specific strength would be.

In certain preferred embodiments, the hollow glass microsphere has oneor more of the following characteristics, which are also generallycharacteristics of harvested cenospheres:

-   an aspect ratio of between about 0.8 and 1;-   a void volume of between about 10 and 95%, based on the total volume    of the microsphere;-   an outer wall thickness of about 2 and 54% of the microsphere    radius.

Referring now to FIG. 3, FIG. 3 is a schematic representation of a glassmelter system 300 in accordance with the present invention.

As mentioned previously in this document, a glass melter system 300 isemployed at least for melting the components of the batch 200. Themelter, one possible configuration of which is shown in FIG. 3,comprises three zones, namely a glass melting zone 310, a glassprocessing zone 320, and a glass discharge zone 330. In the melting zone310, apart from phenomenons that are related to the melting of the batch200 into the first glass melt 206, the RAG components 204 may as well beintroduced. The RAG component 204 is in accordance with one embodimentof the present invention in a gaseous form. Alternatively, additionalRAG components 204 are mixed with the materials of the batch 200 to bemelted. The processing zone 320 is configured such that to allow certainprocesses to take place that are related the first glass melt 206 whilein the melter system 300 including but not limited to: the introductionand incorporation of the RAG components 204 into the first glass melt206, controlling the overall residence time, by storing or releasing thefirst glass melt 206 from the melter system 300, homogenizing the firstglass melt 206, nucleating the first glass melt 206, refining the firstglass melt 206, and reheating the first glass melt 206. The dischargezone 330 comprises one or a combination of a trough, an outlet throat,an airlift system, re-heaters, etc. The RAG components 204 can beincorporated into the first glass melt 206 as well inside the dischargezone 330, right before, and while being discharged from the meltersystem 300.

Although the foregoing descriptions of certain preferred embodiments ofthe present invention have shown, described and pointed out somefundamental novel features of the invention, it will be understood thatvarious omissions, substitutions, and changes in the form of the detailof the apparatus as illustrated as well as the uses thereof, may be madeby those skilled in the art, without departing from the spirit of theinvention. Consequently, the scope of the present invention should notbe limited to the foregoing discussions.

What is claimed is:
 1. Microspheres, comprising: a plurality of hollowmicrospheres, each of said plurality of hollow microspheres comprising:a plurality of glass walls comprising an outer glass wall, and aplurality of hollow spaces, wherein said plurality of glass wallsenclosing at least one of said plurality of hollow spaces; wherein saidouter glass walls consisting of a second glass; wherein said secondglass comprising a processed first glass; wherein said processed firstglass comprising a melt of a batch and a plurality of redox active groupcomponents capable of providing a plurality of redox reactions in saidsecond glass, wherein said second glass having a uniform compositionthroughout, and wherein a concentration of sodium oxide in the secondglass is lower than about 8 wt % of a total weight of said second glass.2. The microspheres of claim 1, wherein said plurality of redoxreactions are non-equilibrium redox reactions.
 3. The microspheres ofclaim 1, wherein at least one of said processed first glass and saidbatch comprising said plurality of redox active group components.
 4. Themicrospheres of claim I, wherein said plurality of redox active groupcomponents comprising components in at least one of a gaseous form, aliquid form, a solid form, an aerosol form and a combination thereof. 5.The microspheres of claim 1, wherein said batch comprising at least onemember selected from the group consisting of raw materials, a pluralityof redox active group components, a recovered material, a plurality ofadditives, and a combination thereof.
 6. The microspheres of claim 5,wherein said recovered material comprising at least one member selectedfrom the group consisting of a silicate material, an aluminosilicatematerial, a borosilicate material, fly ash, bottom ash, incinerationash, slag, waste glass, spent inorganic catalysts, red mud, kiln dust,mine tailings, spent oil shale, residual biomass, an alumina containingmaterial, a titania containing material, a zirconia containing material,a vitrified material and a combination thereof.
 7. The microspheres ofclaim 6, wherein said vitrified material comprising at least one of avitrified asbestos waste material, a vitrified hazardous waste material,a vitrified radioactive waste material, a vitrified incineratedmunicipal waste material, a vitrified incineration ash, a vitrifiedmedical waste material, a vitrified sulfur compound containing material,and a multivalent metal compound containing material.
 8. Themicrospheres of claim 1, wherein said second glass comprising: silica ina concentration from about 30 wt % to about 85 wt %, a monovalent metaloxide in a concentration from about 4 wt % to about 12 wt %, alumina ina concentration from about 2 wt % to about 30 wt %, divalent metal oxidein a concentration from about 2 wt % to about 30 wt %, and a pluralityof oxides and chemical species in a concentration from about 0 wt % toabout 30 wt %, wherein said monovalent metal oxide is one or acombination of lithium oxide, sodium oxide, and potassium oxide, andwherein said divalent metal oxide is one or a combination of magnesiumoxide, calcium oxide, strontium oxide, and barium oxide.
 9. Themicrospheres of claim 1, wherein said plurality of hollow microsphereshaving a composite leach rate of less than about 500 g/m² per day at apH of about 11 and a temperature of about 90° C.
 10. The microspheres ofclaim 1, wherein said second glass comprising sulfide, and wherein aconcentration of sulfide in the second glass is from about 0.001 wt % toabout 2 wt % based on a total weight mass of the second glass.
 11. Themicrospheres of claim 1, wherein the second glass comprising ferrousiron.
 12. The microspheres of claim 1, wherein said plurality of hollowmicrospheres having a specific strength of up to about$340\mspace{14mu}{\frac{MPa}{g/{cc}}.}$
 13. The microspheres of claim 1,wherein a ratio between an average particle size of the plurality ofhollow microspheres and an average particle size of a plurality offragments comprising said second glass is greater than 1 and less thanabout
 3. 14. The microspheres of claim 1, wherein an average diameter ofthe plurality of hollow microspheres is between about 5 microns andabout 1000 microns.
 15. The microspheres of claim 1, a volume of saidplurality of hollow spaces being between about 10% and about 95% of atotal volume of the each of said plurality of microspheres.
 16. Themicrospheres of claim 1, wherein said outer wall having a thickness ofabout 2% to 54% of a radius of said hollow microsphere.
 17. A compositeproduct, comprising: a combination of microspheres according to claim 1,and at least one of a plurality of polymer matrices, a plurality ofcementiteous matrices, a plurality of fluid matrices, a plurality ofsolid matrices, a plurality of fiber containing matrices, and aplurality of metal matrices.
 18. Microspheres, comprising: a pluralityof hollow microspheres, each of said plurality of hollow microspherescomprising: a plurality of glass walls comprising an outer glass wall,and a plurality of hollow spaces, wherein said plurality of glass wallsenclosing at least one of said plurality of hollow spaces; wherein saidouter glass wall consisting of a glass having a uniform compositionthroughout; wherein said glass comprising a second glass processed atleast by injecting a gas into a melt of a first glass; wherein saidsecond glass comprising sulfide, and wherein a concentration of sodiumoxide in the second glass is lower than about 8wt % of a total weight ofsaid second glass.
 19. The microspheres of claim 18, wherein said gascomprising either one or a combination of a carbon comprising compound,a sulfur comprising compound, a hydrogen comprising compound, and anitrogen containing compound.